VCM - Controller Technical Guide · 2019-09-17 · Technical Guide 6 VCM Controller Figure 1: VCM...

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VCM - Controller Technical Guide VCM Controller Code: SS1016 Requires System Manager Code: SS1010 Version 3.0 and up Requires Service Tool Code: SS1009 Version 3.0 and up www.orioncontrols.com

Transcript of VCM - Controller Technical Guide · 2019-09-17 · Technical Guide 6 VCM Controller Figure 1: VCM...

VCM - ControllerTechnical Guide

VCM Controller Code: SS1016Requires System Manager Code: SS1010 Version 3.0 and up

Requires Service Tool Code: SS1009 Version 3.0 and up

www.orioncontrols.com

Table Of Contents

Controller Overview ........................................................................................................................................ 4Features ...................................................................................................................................................................................... 4Applications ................................................................................................................................................................................ 4

Controller Installation & Wiring ...................................................................................................................... 8General ..................................................................................................................................................................................... 10Controller Mounting .................................................................................................................................................................. 10Important Wiring Considerations .............................................................................................................................................. 10

Expansion Board Installation & Wiring ........................................................................................................ 11Jumper Settings ......................................................................................................................................................................... 11Wiring Considerations .............................................................................................................................................................. 12

Input/Output Wiring Details ........................................................................................................................... 14Space Temperature Sensor ...................................................................................................................................................... 14Remote SAT Reset Signal ........................................................................................................................................................ 14Supply & Return Temperature Sensor ...................................................................................................................................... 15Outdoor Air Temperature Sensor .............................................................................................................................................. 17Economizer Damper Actuator ................................................................................................................................................... 18Suction Pressure Transducer ................................................................................................................................................... 19Supply Fan VFD Signal Or Zoning Bypass Damper Actuator .................................................................................................. 21Binary Inputs Wiring ................................................................................................................................................................. 22Outdoor Air Humidity Sensor .................................................................................................................................................... 23Indoor Wall Mounted Humidity Sensor ..................................................................................................................................... 24Return Air Mounted Humidity Sensor ....................................................................................................................................... 25Building Pressure Sensor Wiring .............................................................................................................................................. 26Building Pressure ControlOutput Wiring ............................................................................................................................................................................ 27CO2 Sensor Wiring ................................................................................................................................................................... 28Modulating Heating Device Wiring ........................................................................................................................................... 29Modulating Cooling Device Wiring ........................................................................................................................................... 30Return Air Bypass Wiring .......................................................................................................................................................... 31

Start-up & Commissioning ............................................................................................................................ 32Controller Addressing ............................................................................................................................................................... 32Power Wiring ............................................................................................................................................................................ 32Initialization: .............................................................................................................................................................................. 33Operating Summary .................................................................................................................................................................. 33Programming The Controller .................................................................................................................................................... 33

Inputs & Outputs ........................................................................................................................................... 34VCM Controller ......................................................................................................................................................................... 34OE354 (4) Analog Input(1) Analog Output Expansion Board ......................................................................................................................................... 35OE355 (4) Analog OutputExpansion Board ...................................................................................................................................................................... 35OE357 (4) Relay Expansion Boards ......................................................................................................................................... 35OE356 Binary Expansion Board #1 .......................................................................................................................................... 36OE356 Binary Expansion Board #2 .......................................................................................................................................... 36

WattMaster Controls Inc.8500 NW River Park Drive · Parkville , MO 64152Toll Free Phone: 866-918-1100PH: (816) 505-1100 · FAX: (816) 505-1101 · E-mail: [email protected] our web site at www.orioncontrols.com

Form: OR-VCM-TGD-01A Copyright 2005 WattMaster Controls, Inc.AAON® is a registered trademark of AAON, Inc., Tulsa, OK.WattMaster Controls, Inc. assumes no responsibility for errors, or omissions.This document is subject to change without notice.

www.orioncontrols.com

VCM Controller

Technical Guide

3

Sequence Of Operations ............................................................................................................................... 37Occupied/UnoccupiedMode of Operation .................................................................................................................................................................... 37HVAC Modes of Operation ....................................................................................................................................................... 37Vent Mode Operation ................................................................................................................................................................ 37Cooling Mode Operation ........................................................................................................................................................... 37Dehumidification Mode ............................................................................................................................................................. 39Remote Forced Dehumidification ............................................................................................................................................. 40Return Air Bypass Damper Control .......................................................................................................................................... 40Heating Mode Operation .......................................................................................................................................................... 40Warm-up Mode Operation ........................................................................................................................................................ 42Off Mode ................................................................................................................................................................................... 42Remote Control of HVAC Mode................................................................................................................................................ 42Supply Air TemperatureSetpoint Reset .......................................................................................................................................................................... 42Supply Fan Control ................................................................................................................................................................... 43Duct Static Pressure Control .................................................................................................................................................... 43Building Pressure Control ......................................................................................................................................................... 43IAQ (CO2) Operation ................................................................................................................................................................ 44Pre-heater Operation ................................................................................................................................................................ 44Outdoor Air Lockouts ................................................................................................................................................................ 44Supply Air Cutoffs ..................................................................................................................................................................... 44Scheduling ................................................................................................................................................................................ 44Internal Trend Logging .............................................................................................................................................................. 45Force Modes or Overrides ........................................................................................................................................................ 45VAV/Zone Box Compatibility ..................................................................................................................................................... 46VAV/Zone System ..................................................................................................................................................................... 46Zoning System .......................................................................................................................................................................... 46

Troubleshooting ............................................................................................................................................ 47Using LEDs To Verify Operation ............................................................................................................................................... 47

Appendix ........................................................................................................................................................ 48Diagnostic LEDs Operation ...................................................................................................................................................... 48System Configuration Options .................................................................................................................................................. 4910 kOhm Type III Temperature Sensor Testing ........................................................................................................................ 53OE265 RH Sensor Testing ....................................................................................................................................................... 54OE271 Pressure Sensor Testing .............................................................................................................................................. 55OE258 Pressure Sensor Testing .............................................................................................................................................. 55OE275 Suction Pressure Transducer Testing ........................................................................................................................... 56

Notes: ............................................................................................................................................................ 57

Technical Guide

VCM Controller4

FeaturesThe VCM Controller Board is designed with 7 analog inputs, 2 analogoutputs and 5 relay outputs. The controllers input and output capabili-ties can be expanded by use of either 2 slot or 4 slot expansion boardsthat plug into the VCM Controller by means of a modular cable. TheVCM Controller can be configured for control of VAV Units (with orwithout VAV/Zone Controllers), Constant Volume Units and Make-upAir Units. Features include the following:

• Up to a Combined Total of 20 Stages of Heating & Cooling

• Modulating Cooling Output (Digital Compressor or ChilledWater Valve Control)

• Modulating Heating Output (Hot Water Valve, Steam Valve,SCR Electric Heat Control)

• Full Integration with the AAON®

MODGAS II Modulating Natural Gas Controller

• Full Integration with the AAON® MHGRV II ModulatingHot Gas Reheat Controller

• Configurable for Air to Air Heat Pump Applications

• Advanced Dehumidification Capabilities

• Primary/Secondary Heating Control

• Automatic Supply Air Reset

• Selectable Control Sensor

• Fan Proving Interlock

• Dirty Filter Alarm

• Smoke Detector Input

• Drybulb/Wetbulb Control of Economizer Operation

• Building Pressure Control

• Remote Override Capabilities

• I.A.Q. Economizer Reset

• 7 Day, 2 Event per Day Scheduling

• 14 Holiday Event Scheduling

• Optimal Start Scheduling

• Trend Logging Capability

• Static Pressure Control For Filter Loading Applications

• Accepts Remote HVAC Mode Selection Via ContactClosure On Expansion Input Board

• Configurable for PAC and DPAC Applications

Controller OverviewMost common HVAC unit control applications can be configured usingonly the VCM Controller board. If the application requires more inputsand/or outputs, optional expansion boards are available to provide foradditional analog, binary or digital inputs and outputs as required. Theseexpansion boards are installed on either a 2 slot or 4 slot expansion baseboard that connects to the VCM Controller board via a modular cableconnection.

The available expansion board configurations allow for (8) additionalbinary inputs, 4 additional analog inputs, 1 additional analog output,and up to 16 additional binary (relay) outputs. The various expansionboards connect to the 2 slot or 4 slot expansion base boards. Jumperslocated on the base boards near each expansion board socket must beset according to the board type installed on that socket.

ApplicationsVariable Air Volume UnitThe VCM can be configured to control a VFD Supply Fan for DuctStatic Pressure control. If the unit is not equipped with a VFD, but DuctStatic Pressure control is needed, a modulating Zoning Bypass Dampercan be controlled by the VCM.

VAV units are typically designed for occupied Cooling with MorningWarm-up Heating. This option is available with the VCM. The VCMcan also be used for a Zoning System that needs Duct Static Pressurecontrol and Occupied Cooling and Heating. The VCM also has the abil-ity to be configured for Duct Static Pressure Control by controlling theSupply Fan VFD for the purpose of maintaining proper Duct StaticPressure in response to varying filter loading conditions.

The VCM allows Dehumidification Priority on a VAV unit. This couldbe useful on a building with very low internal sensible load, but has ahigh internal and/or external latent load. During VAV Dehumidificationthe VCM activates Cooling based on the Evaporator Coil Temperatureand activates Modulating Hot Gas Reheat to warm the Supply Air Tem-perature to the Active Supply Air Temperature Setpoint.

Constant Air Volume UnitThe VCM can be configured to activate a Constant Volume SupplyFan. In most cases, this is a very basic unit with Space Temperaturecontrol. The VCM can be used for kitchen, restaurant or lab environ-ments that are 100% Outdoor Air part of the time and return air part ofthe time. The Hood On input allows the VCM to know when to switchto 100% Outdoor Air control based on an exhaust hood activating. TheVCM requires Outdoor and Indoor Air Temperature Sensors to accom-plish this application.

Make-up Air UnitThe VCM can be configured for 100% Outdoor Air control for Make-up Air. All HVAC Modes are determined from the Outdoor Air Sensors.The Outdoor Air Volume must always be at least 50% or higher to beconfigured for Outdoor Air control.

VCM Controller

Technical Guide

5

Air to Air Heat Pump UnitThe VCM can be configured to control an Air to Air Heat Pump. Thecompressors are used for both Heating and Cooling. With the VCMcontroller the Reversing Valve is activated during Heating operation asthe default because AAON units are typically built to fail to Coolingoperation. The Reversing Valve can be configured to activate duringCooling operation for equipment that is built to fail to Heating opera-tion.

Auxiliary Heating Stages are configured as Heat Relays and are used tosupplement the Compressor Heating Stages. If the unit is not equippedwith Auxiliary Heating Stages, Heating Relays do not need to be con-figured in order for the unit to provide Heating. Auxiliary Heating canalso be Modulating heat in the form of SCR Electric, Hot Water orSteam.

The Cooling and Dehumidification Modes operate in the same manneras described under the Cooling and Dehumidification titled sections ofthis manual. In the Heating Mode, the VCM activates the ReversingValve and stages compressors to provide Heating if the Outdoor AirTemperature is above the OAT Cooling Lockout Setpoint. The com-pressor heating stages are activated as needed to achieve the ActiveSupply Air Setpoint. Staged or Modulating Auxiliary Heat can be acti-vated to supplement Compressor Heating in order to achieve the ActiveSupply Air Setpoint if the Outdoor Air Temperature is below the OATHeating Lockout Setpoint. If the Outdoor Air Temperature is below theOAT Cooling Lockout Setpoint, only Auxiliary Heating will occur. Ifthe Outdoor Air Temperature is above the OAT Heating Lockout, onlyCompressor Heating will occur.

PAC (Precision Air Control)This control scheme can only be used on Constant Volume HVACunits that are equipped with a Return Air Bypass Damper and use aSpace Temperature Sensor as the Controlling Sensor.

PAC Control provides improved moisture removal capabilities whileutilizing internal space loads for reheat by redirecting the Return Airpath from the upstream side of the DX Evaporator Coil to the down-stream side of the coil.

For PAC configured units, the Return Air Bypass Damper is only usedduring the Dehumidification Mode. When the VCM controller is in De-humidification Mode, the Return Air Bypass Damper will modulateopen as the Space Temperature falls below the Cooling Setpoint. Modu-lation of the Return Air Bypass Damper is controlled using a propor-tional range from 0% (when the Space Temperature is equal to the Cool-ing Setpoint), up to 100% (when the Space Temperature falls to thehalfway point between the Cooling and Heating Setpoints). A separate,Return Air Damper Actuator will modulate the Return Air Damperslightly further towards its closed position as the Return Air BypassDamper opens. This is to ensure that enough Return Air is bypassedaround the Evaporator Coil through the Return Air Bypass Damper toraise its temperature. The rate which the Return Air Damper closes whilethe Return Air Bypass Damper is open is user adjustable.

DPAC – Digital Precision Air ControlThis control scheme can only be used on Constant Volume HVAC unitsthat are equipped with a Return Air Bypass Damper, a Digital Com-pressor and use a Space Temperature Sensor as the Controlling Sensor.

The DPAC control scheme provides improved moisture removal capa-bilities over the PAC control scheme and provides for tighter tempera-ture control by combining a Digital Compressor with the Return AirBypass Damper. See the Cooling Mode section of this manual for de-tailed Digital Compressor operation. See the PAC Control previouslydescribed in this section for detailed Return Air Bypass Damper opera-tion.

The Digital Compressor is used during both Cooling and Dehumidifi-cation Modes. The Return Air Bypass Damper is used only during theDehumidification Mode.

Technical Guide

VCM Controller6

Figure 1: VCM Controller Dimensions

RLY

1

D1

D2

D3

D4

D5

CX

3

RAM EPROM

C3

C2

U6

CX6

C1

CX2U2

U3

PAL

CX4

U4

TUC-5R PLUS

YS101816 REV. 2

V1

V2

V3

V5

V4

TB2

4

NETWORK

TOKEN

16

32

8

SW1

ADD

2

1

ADDRESS

V6

PO

WE

R

GND

24VAC

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6

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SC1

R11

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D1

3

C16

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7

C13

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0

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C1

9

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8

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CX

8U9

X1

R7D1

0

R13D12

C7CX10

U10

CX12

U12

U14

CX14

PJ3

PJ2

PJ1

EXPANSION

PRESSURESENSOR

T'STAT

C17D15

R26

C20 R25

R24

R22

U15

CX13

U13

C15

R19

R15

C14

D1

8

D1

7

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D6

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INPUTS

GND

GND

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AIN2

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AIN4

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RS-485

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COMM

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5.11V

TEST POINT

EWDOG

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1

COM1-3

COM4-5

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R4

R3

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RLY

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(1 MEG)HH

P1

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1

6.2“

6.6”7.3”

6.7”

.20 Dia.Typ. of 4

Controller Overview

VCM Controller

Technical Guide

7

Figure 3: Expansion Boards Dimensions

Figure 2: Expansion Base Boards Dimensions

4.00”

OE3544 Analog Input 1 AnalogOutput Expansion Board

OE3574 Relay Output

Expansion Board

OE3564 Binary Input

Expansion Board

OE3554 Analog OutputExpansion Board

4.24”

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2

R6

CX

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0

R4

R5

P2

JP2

OE352 2 Slot Expansion Base Board

OE353 4 Slot Expansion Base Board

Technical Guide

VCM Controller8

RS-485CommunicationsLoop Connection

TypicalPin 1Indicator

RAMChip

EPROMChip

PALChip

RS-485CommunicationsDriver Chip

Real TimeClock Chip

MountingBackplate

Mounting HoleTyp of 4

CommLED

PowerLED

DiagnosticBlink CodeLEDs

Modular ServiceTool - Mini DinConnector

Address Switch

Pull-up ResistorsFor Analog Inputs

Analog InputAnd OutputTerminal Block

24 VACPower Input

EEPROM

Relay OutputTerminal Block

Duct Static Pressure Sensor(AIN6 Modular Connection)

Expansion Board(Modular Connection)

DigiSensor(Modular Connection)

RLY

1

D1

D2

D3

D4

D5

CX

3

RAM EPROM

C3

C2

U6

CX6

C1

CX2U2

U3

PAL

CX4

U4

TUC-5R PLUS

YS101816 REV. 2

V1

V2

V3

V5

V4

TB2

4

NETWORK

TOKEN

16

32

8

SW1

ADD

2

1

ADDRESS

V6

PO

WE

R

GND

24VAC

L1

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R6

C9

SC1R

11

U11

D13

C16

VR2

TB4

R27

C13

R10

VR1

C19

C18

U8

CX

8

U9

X1

R7D10

R13D12

C7CX10

U10

CX12

U12

U14

CX14

PJ3

PJ2

PJ1

EXPANSION

PRESSURESENSOR

T'STAT

C17D15

R26

C20 R25

R24

R22

U15

CX13

U13

C15

R19

R15

C14

D18

D17

PU1

PU2

PU3

PU4

PU5

PU7

D6

D7

D8

D9

D11

D14

C12

C10 0-5

VD

C

0-1

VD

C

JP1

C11

X2

GNDTB3

INPUTS

GND

GND

+VDC

AIN1

AIN2

AIN3

AIN4

AIN5

AOUT1

AOUT2

AIN7

RN

4

1

RN5

RS-485

CX5

U5

R

TB1

SHLD

T

COMM

COMM

RN

3

1

RN1

U1

CX1

1

LD6

COMM

PWRLD7

LED1

LED2

LD9

LD8

R1

U7

RV1

VREF ADJ R28

+VREF

5.11V

TEST POINT

EWDOG

D19

RN

2

1

COM1-3

COM4-5

R5

R4

R3

R2

R1

RLY

2R

LY

3R

LY

4R

LY

5

CX15

(1 MEG)HH

P1

C21

Figure 4: VCM Controller Component Locations

Controller Installation & Wiring

VCM Controller

Technical Guide

9

Lin

eV

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Technical Guide

VCM Controller10

Controller Installation & WiringGeneralCorrect wiring of the VCM controller is the most important factor inthe overall success of the controller installation process. In general mostVCM controllers are factory installed and wired at the AAON® factory.It is also possible to purchase these controllers directly from WattMasterControls for installation in the field. Some of the following informationpertains to field wiring and may not apply to your installation since itwas pre-wired at the factory. However, in the unlikely event that trouble-shooting of the controller is required, it is a good idea to be familiarwith the system wiring, no matter if it was factory or field wired.

Controller MountingWhen the controller is to be field mounted, it is important to mount thecontroller in a location that is free from extreme high or low tempera-tures, moisture dust and dirt. See Table 1 for a list of the required oper-ating conditions for the VCM Controller and associated expansionboards.

Be careful not to damage the electronic components when mountingthe controller. Remove the controller from its backplate. Mark the con-trol enclosure base using the backplate as a template. Drill pilot holes inthe enclosure base and secure the backplate to it using sheet metal screws.Do not allow metal shavings to fall onto the circuit board. Reattach thecontroller to the backplate.

Important Wiring ConsiderationsThe VCM controller and expansion boards must be connected to a 24VAC power source of the proper size for the calculated VA load re-quirements. All transformer sizing should be based on the VA ratinglisted in Table 1.

ControlDevice

Vol

tage

VA

Loa

d

Ope

rati

ngT

empe

ratu

re

Ope

rati

ngH

umid

ity

VCM ControllerBoard

24VAC60Hz

8 10°F to 149°F 90% RH*N.C.

2 Slot ExpansionBase Board

24VAC60Hz

10 10°F to 149°F 90% RH *N.C.

4 Slot ExpansionBase Board

24VAC60Hz

20 10°F to 149°F 90% RH*N.C.

* Non-Condensing

Table 1: Voltage and Environment Requirements

Warning: When using a single transformer to power morethan one controller or expansion board, the correctpolarity must always be maintained between theboards. Failure to observe correct polarity willresult in damage to the VCM controller andexpansion boards.

Please carefully read and apply the following information when wiringthe VCM controller or the VCM Expansion Boards. See Figure 5 forVCM controller wiring diagram. See Figures 6, 7 and 8 for ExpansionBoard Wiring.

1. All wiring is to be in accordance with local and national

electrical codes and specifications.

2. Minimum wire size for 24 VAC wiring should be 18 gauge.

3. Minimum wire size for all sensors should be 24 gauge.

Some sensors require 2 conductor wire and some require 3

or 4 conductor wire.

4. Be sure that all wiring connections are properly inserted

and tightened into the terminal blocks. Do not allow wire

strands to stick out and touch adjoining terminals which

could potentially cause a short circuit.

5. When communication wiring is to be used to interconnect

VCM controllers together or to connect to other

communication devices, all wiring must be plenum rated,minimum 18 gauge, 2 conductor, twisted pair with shield.WattMaster can supply communication wire that meets this

specification and is color coded for the network or local

loop. Please consult your WattMaster distributor for

information. If desired, Belden #82760 or equivalent wire

may also be used.

6. Before applying power to the VCM controller, be sure

to recheck all wiring connections and terminationsthoroughly.

VCM Controller

Technical Guide

11

Figure 6: Expansion Board Jumper and Pullup Resistor Settings

Jumper SettingsSeveral different Expansion Boards are available for use with the VCMController to provide additional inputs and outputs beyond those foundon the VCM Controller board. These Expansion Boards are mounted toeither the OE352, 2 slot Expansion Base Board(s) or the OE353, 4 slotExpansion Base Board(s) depending on the total number of expansionboards to be used with your particular application.

The OE352 2 Slot Expansion Base board or the OE353 4 Slot Expan-sion Base boards are connected to the VCM Controller and to eachother with modular cables. A maximum of (2) Expansion Base Boardstotal, (4 slot, 2 slot or a combination of both) can be connected to theVCM controller.

The VCM controller uses the following expansion boards. The maxi-mum quantities of each expansion board that can be used for each VCMcontroller are also listed.

OE354 4 Analog Input 1 Analog Output Expansion Board

(1 per VCM Controller)

OE355 4 Analog Output Expansion Board(1 per VCM Controller)

OE356 4 Binary Input Expansion Board

(Up to 2 boards per VCM Controller)

OE357 4 Relay Output Expansion Board

(Up to 4 boards per VCM Controller)

The various Expansion Boards can be mounted on the Expansion BaseBoard in any order, however, the address jumpers located near eachExpansion Board plug-in socket must be set correctly for the Expan-sion Board that is connected to that socket. In addition the OE354, 4Analog Input 1 Analog Output Expansion Board also has Voltage Jump-ers (J01, J02, J03 & J04) and Pullup Resistors (PU1, PU2, PU3, &PU4) that must be correctly configured for proper Expansion Boardoperation. See Figure 6 for the correct address jumper, voltage jumperand Pullup resistor settings for the VCM application.

Expansion Board Installation & Wiring

JO3

JO4

JO2

JO1

CX

2

R10

AOUT1

AIN4

TB1

GND

AIN2

AIN3

AIN1

PU4

U2

D5

Q1

R8

R9

LM358

C5

C1

R7

R6

R5

PU3

C4

C3

C2

PU2

PU1

4 ANALOG IN MOD. I/O BD.

R3

PC

F8

59

1P

YS101784

D4

R4

D3

D1

D2

R2

R1

PHILIPS

T L

HA

AN

I D

CX1

U1

P1

JumpersUnderExpansionBoard To BeSet As Shown

JumpersUnderExpansionBoard To BeSet As Shown

JumpersUnderExpansionBoard To BeSet As Shown

JumpersUnderExpansionBoard To BeSet As Shown

OE354 4 Analog Input - 1 Analog Output Expansion Board OE355 4 Analog Output Expansion Board

OE356 4 Binary Input Expansion Board #2OE356 4 Binary Input Expansion Board #1

R4R4

R3R3

R2R2

R1R1

YS101788YS101788

BIN 4BIN 4

BIN 3BIN 3

BIN 2BIN 2

BIN 1BIN 1

COMCOM

TB1

TB1

OPTO2OPTO2

R10R10

R12R12

4 DIG. IN MOD. I/O BD.4 DIG. IN MOD. I/O BD.

P2

50

6-2

P2

50

6-2

R8R8

R6R6

R5R5

P2

50

6-2

P2

50

6-2

OPTO1OPTO1

74

HC

14

N

74

HC

14

N

PC

F8

57

4P

PC

F8

57

4P

U2U2

C4

C4

C3

C3

U1U1

CX2CX2

C2

C2

C1

C1

CX1CX1

P1

P1

Jumper On = 0-10VDC Input Setting

For Proper Operation Pullup Resitors PU1, PU2,PU3 & PU4 Must Be Removed As Shown

Address Jumpers Address Jumpers

Address JumpersAddress Jumpers

Jumper Must Be Off For AIN1, 2 & 4Jumper Must Be ON For AIN3

Jumper Off = 0-5 VDC Input Setting

GND

AOUT1

YS1017864 AOUT MOD. I/O BD.

CX1

U1

Q1

LM

358

R2 U2

R9

D1

R6

D2

R7

D4

D3

R8

TB

1

CX2

C3

C1

P1

RV

1

R1

C4 U3

C2

LM

358

CX3

AOUT2

AOUT3

AOUT4

Q2

R3

Q4

Q3

R4

R5

JumpersUnderExpansionBoard To BeSet As Shown

OE357 4 Relay Output Expansion Board

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

K3

K2

4RLY IO BD.

V4

K4

YS101790

TB1

V1

K1

K3

U2

K4

RN1

PCF8574P

U1

T L

HA

AN

I D

ULN2803A/

K2

K1

74HC04N

PHILIPS

P1

CX

2

CX

1

Relays 6-9 Relays 10-13 Relays 14-17 Relays 18-21

Address Jumpers

Technical Guide

VCM Controller12

Expansion Board Installation & Wiring

Figure 7: Expansion Board Wiring Details For Binary Input, Analog Input and Analog Output Boards

R20

C8

TB2

D3

PW

R

LD

1

24

VA

C-IN

GN

D

GN

D

TB1

PJ2

+2

4VD

C-O

UT

R1

7

PJ1

R1

5

R4

R3

R2

R1

YS101788

BIN 4

BIN 3

BIN 2

BIN 1

COM

TB1

OPTO2

R10

R12

4 DIG. IN MOD. I/O BD.

P2

50

6-2

R8

R6

R5

P2

50

6-2

OPTO1

74

HC

14

N

PC

F8

57

4P

U2C4

C3

U1

CX2

C2

C1 CX1

P1

R4

R3

R2

R1

YS101788

BIN 4

BIN 3

BIN 2

BIN 1

COM

TB1

OPTO2

R10

R12

4 DIG. IN MOD. I/O BD.

P2

50

6-2

R8

R6

R5

P2

50

6-2

OPTO1

74

HC

14

N

PC

F8

57

4P

U2C4

C3

U1

CX2

C2

C1 CX1

P1

OE

35

6-4

Bin

ary

Inp

ut

Bo

ard

#1

OE

35

6-4

Bin

ary

Inp

ut

Bo

ard

#2

OE

35

5-

4A

na

log

Ou

tpu

tB

oa

rd

Remote Forced Heating - N.O. Contact

Remote Forced Cooling - N.O. Contact

Hood On - N.O. Contact

Dirty Filter - N.O. Contact

Proof Of Flow - N.O. Contact

Remote Forced Occupied - N.O. Contact

+

COM

+

COM

VOUT (0-5V)

GND

VIN

VAC OR DC

GND

0-5V

0-10V OUTPUT

SIGNAL GROUND

+-

AC/GND

AC+/DC+

LO

W

HIG

H

COM

COM

OUT

EXC++

+

Smoke Detector - N.C. Contact

Remote Forced Dehumidification

N.O. Contact

AOUT2

AOUT4

GND

AOUT1

AOUT3

COM

BIN4

BIN3

BIN2

BIN1

COM

BIN3

BIN4

BIN1

BIN2

Plastic Tubing To BuildingPressure Sensing Locations

Building PressureRelief FAN VFD

Modular CableConnect To VCM Controller

Modular CableConnect To Next Expansion Board

(When Used)

24

VA

C

GN

D

Orion - OE258 Building PressureTransducer

Orion - OE255 Room Mounted CO2 SensorOr

Orion - OE256 Return Air Mounted CO2 Sensor

Orion - OE265-13 Outdoor AirHumidity Sensor

Orion OE265-11 Indoor AirHumidity Sensor

Modulating Heating(0 to 10 VDC Input)

Modulating CoolingOr Digital Scroll Compressor

(1.5 to 5, 0 to 10 or 2 to 10 VDC Input)

Return Air BypassDamper Actuator

(0-10 VDC)

Return AirDamper Actuator

(0-10 VDC)

Belimo Actuator WiringShown. Consult Factory ForOther Manufacturers Wiring

Instructions

When Copeland Scroll Compressor IsUsed Wire Per Copeland Digital ScrollWiring Detail

OE352 2 Slot Or OE353 - 4 Slot Expansion BoardAs Required - OE353 Is Shown

10 VA Minimum Power Required ForEach OE352 - 2 Slot Expansion Base Board.

20 VA Minimum Power Required ForEach OE353 - 4 Slot Expansion Base Board

WARNING!!Observe Polarity! All boards must be wired with GND-to-GND and 24VAC-to-24VAC. Failure to observepolarity will result in damage to one or more of the boards. Expansion Boards must be wired in such a way thatpower to both the expansion boards and the controller are always powered together. Loss of power to theexpansion board will cause the controller to become inoperative until power is restored to the expansion board.

JO3

JO4

JO2

JO1

CX

2

R10

AOUT1

AIN4

TB1

GND

AIN2

AIN3

AIN1

PU4

U2

D5

Q1

R8

R9

LM358

C5

C1

R7

R6

R5

PU3

C4

C3

C2

PU2

PU1

4 ANALOG IN MOD. I/O BD.

R3

YS101784

D4

R4

D3

D1

D2

R2

R1 CX1

U1

P1

OE

35

4-

4A

na

log

Inp

ut

-1

An

alo

gO

utp

ut

Bo

ardAIN3

AOUT1

GND

AIN4

AIN1

AIN2

GND

AOUT1

YS1017864 AOUT MOD. I/O BD.

CX1

U1

Q1

LM

35

8

R2 U2

R9

D1

R6

D2

R7

D4

D3

R8

TB

1

CX2

C3

C1

P1

RV

1

R1

C4 U3

C2

LM

35

8

CX3

AOUT2

AOUT3

AOUT4

Q2

R3

Q4

Q3

R4

R5

Y1 3

Y1 3

+ 2

+ 2

COM 1

COM 1

Wiring ConsiderationsThe expansion base boards must be connected to 24 VAC as shown inthe wiring diagram below. Please see Table #1 for correct VA require-ments to use when sizing the transformer(s) used for powering the ex-pansion base boards.

Also please note that when wiring the OE356 - 4 Binary Input Expan-sion Board(s), its contacts must be wired as wet contacts (connected to24 VAC) not dry contacts as used with the OE357 - 4 Relay ExpansionBoards . See Figures 7 and 8 for complete wiring details.

VCM Controller

Technical Guide

13

R20

C8

TB2

D3

PW

R

LD

1

24

VA

C-IN

24

VA

C-IN

GN

DG

ND

GN

D

TB1

PJ2

+2

4VD

C-O

UT

R1

7

PJ1

R1

5

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

K3

K2

4RLY IO BD.

V4

K4

YS101790

TB1

V1

K1

K3

U2

K4

RN1PCF8574P

U1

ULN2803A/

K2

K1

74HC04N

P1

CX

2

CX

1

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

K3

K2

4RLY IO BD.

V4

K4

YS101790

TB1

V1

K1

K3

U2

K4

RN1

PCF8574P

U1

ULN2803A/

K2

K1

74HC04N

P1

CX

2

CX

1

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDCK3

K2

4RLY IO BD.

V4

K4

YS101790

TB1

V1

K1

K3

U2

K4

RN1

PCF8574P

U1

ULN2803A/

K2

K1

74HC04N

P1

CX

2

CX

1

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

UL5A250VAC

G5L-114P-PS

OMRON

CONTACT:

24VDC

K3

K2

4RLY IO BD.

V4

K4

YS101790

TB1

V1

K1

K3

U2

K4

RN1

PCF8574P

U1

ULN2803A/

K2

K1

74HC04N

P1

CX

2

CX

1

Configurable Relay Output # 6

Configurable Relay Output # 10

Configurable Relay Output # 14

Configurable Relay Output # 18

Configurable Relay Output # 7

Configurable Relay Output # 11

Configurable Relay Output # 15

Configurable Relay Output # 19

Configurable Relay Output # 8

Configurable Relay Output # 12

Configurable Relay Output # 16

Configurable Relay Output # 20

Configurable Relay Output # 9

Configurable Relay Output # 13

Configurable Relay Output # 17

Configurable Relay Output # 21

24

VA

C

GN

D

Note:All Relay Outputs AreNormally Open And RatedFor 24 VAC Power Only.2 Amp Maximum Load.

OE

357

-4

Rela

yO

utp

utB

oard

OE

357

-4

Rela

yO

utp

utB

oard

OE

357

-4

Rela

yO

utp

utB

oard

OE

357

-4

Rela

yO

utp

utB

oard

Modular CableConnect To VCM Controller

Modular Cable Connect ToNext Expansion Base Board

(When Used)

10 VA Minimum Power Required ForEach OE352 - 2 Slot Expansion Base Board.

20 VA Minimum Power Required ForEach OE353 - 4 Slot Expansion Base Board

WARNING!!Observe Polarity! All boards must be wired with GND-to-GND and 24VAC-to-24VAC. Failure to observepolarity will result in damage to one or more of the boards. Expansion Boards must be wired in such a way thatpower to both the expansion boards and the controller are always powered together. Loss of power to theexpansion board will cause the controller to become inoperative until power is restored to the expansion board.

OE352 2 Slot Or OE353 - 4 Slot Expansion BoardAs Required - OE353 Is Shown

Figure 8: Expansion Board Wiring Details For Relay Expansion Boards

Technical Guide

VCM Controller14

Input/Output Wiring Details

OE210,OE211, OE212 or OE213Space Temperature Sensor

OVROVR

AUX

GND

TEMP

AIN7

GND

AIN1

Note:Either The Slide Offset Option For The SpaceTemperature Sensor Or The Remote Supply AirTemperature Reset Signal Option (by Others) May BeConnected To AIN7 On The VCM Controller. OnlyOne Option Is Allowed, Not Both.

Optional Slide OffsetWiring Connection ForOE212 or OE213Sensor Only

Figure 10: Remote Supply Air Temperature Reset Signal Wiring

Space Temperature SensorThe Space Temperature Sensor is typically used for constant volumeHVAC unit applications controlling one zone. The Space TemperatureSensor is a 10K Type III thermistor sensor. The Space TemperatureSensor should be mounted approximately 5 ft. above the floor in thespace that is to be controlled. The Space Temperature Sensor is avail-able in a sensor only, sensor with override button, sensor with slideadjust and sensor with slide adjust and override configurations.

When the Remote Supply Air Temperature Reset Signal option is neededthe Slide Offset option on the Room Sensor cannot be used. Only oneof these options may be used on the VCM controller.

See Figure 9 for complete Space Temperature Sensor wiring details.

Remote SAT Reset SignalA Remote Supply Air Temperature Reset Signal can be connected toAIN 7 for applications requiring remote reset of the Supply Air Tem-perature Setpoint.

When the Slide Offset option on the Room Sensor is used, the RemoteSupply Air Temperature Reset Signal cannot be used. Only one of theseoptions may be used on the VCM controller.

The VCM controller can accept either a 0-5 VDC signal or a 0-10 VDCsignal on this input. When a 0-10 VDC signal is to be used, a resistormust be installed. See Figure 10 for complete Remote Supply Air Tem-perature Reset Signal wiring details.

Remote Supply AirTemperature Reset Signal

(By Others)

AIN7

GND

0-5 VDC or 0-10 VDC Signal

GND

Pullup Resistor PU7 Must BeRemoved When Using TheRemote Supply Air Temperature

Signal InputReset

Note:Either The Slide Offset Option For The SpaceTemperature Sensor Or The Remote Supply AirTemperature Reset Signal Option (by Others) May BeConnected To AIN7 On The VCM Controller. OnlyOne Option Is Allowed, Not Both.

Note:When Using 0-10 VDC For The Remote SignalSource Must Have (2) 10kOhm Resistors Wired AsShown. When Using 0-5 VDC For The RemoteSignal These Resistors are Not Required And TheSignal Can Be Wired Directly To AIN7 and GND,

10 kOhm ResistorsUsed With 0-10 VDCSignal Only

Figure 9: Space Temperature Sensor Wiring

VCM Controller

Technical Guide

15

Figure 11: Supply Air and Return Air Temperature Sensor Wiring- Units Without MODGAS II or MHGRV II

GND

INPUTS

GNDAOUT1

AOUT2

GND

+VDC

AIN1

AIN2

AIN3

AIN4

AIN5

AIN7

Mount In HVACUnit Supply

Air Duct

Mount In HVACUnit Return

Air Duct OE331-21-VCMVCM Controller Board

OE231Supply Air Temperature Sensor

OE231Return Air Temperature Sensor

Supply & Return Temperature SensorFor applications that do not use either the AAON® MODGAS II orMHGRV II boards, the Supply Air & Return Air Temperature Sensorsmust be wired as shown in the Figure 11 for proper operation. TheSupply Air & Return Air Temperature Sensors are 10K Type III ther-mistor sensors. The Supply Air Temperature Sensor should be mountedin the unit discharge plenum or in the supply air duct. The Return AirTemperature Sensor should be mounted in the return air duct. If thesystem has a Zoning Bypass Damper installed, be sure the return airsensor is located upstream of the bypass duct connection.

Note: If your AAON® HVAC unit uses the MODGAS IIController and/or the MHGRV II Controller, theSupply Air Sensor must be wired to one of thesecontrollers and not to the VCM Controller.

Please see Figure 12 for Supply Air Temperature Sensor Wiring whenusing the MODGAS II controller and/or the MHGRV II controller. TheReturn Air Temperature Sensor always connects to the VCM controlleras shown in Figure 11

Technical Guide

VCM Controller16

Input/Output Wiring Details

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PW

RL

D7

LE

D1

LE

D2

LD

9

LD

8

R1

U7 RV

1V

RE

FA

DJ

R2

8

+V

RE

F 5.1

1V

TE

ST

PO

INT EW

DO

G

D1

9

RN21

COM4-5

R5

R4

R3

R2

R1COM1-3

Ex

pa

ns

ion

Ba

se

Bo

ard

Co

nn

ec

tio

n(W

he

nU

se

d)

(s)

Ex

pa

ns

ion

Ba

se

Bo

ard

Co

nn

ec

tio

n(W

he

nU

se

d)

(s)

To

Oth

er

Ex

pa

ns

ion

Ba

se

Bo

ard

(Wh

en

Us

ed

)(s

)

PJ1

PJ1

IC

OU

T2

IC

OU

T2

IC

IN2

IC

IN2

OE

23

1S

up

ply

Air

Se

ns

or

OE

23

1S

up

ply

Air

Se

ns

or

OE

23

1S

up

ply

Air

Se

ns

or

OE

33

1-2

1-V

CM

VC

MC

on

tro

lle

rB

oa

rdO

E3

31

-21

-VC

MV

CM

Co

ntr

oll

er

Bo

ard

OE

33

1-2

1-V

CM

VC

MC

on

tro

lle

rB

oa

rdO

E3

31

-21

-VC

MV

CM

Co

ntr

oll

er

Bo

ard

VCM Controller

Technical Guide

17

GND

INPUTS

GNDAOUT1

AOUT2

GND

+VDC

AIN1

AIN2

AIN3

AIN4

AIN5

AIN7

OE250Outdoor Air

Temperature Sensor

Make Splice ConnectionsInside Sensor EnclosureAs Shown. Seal AllConduit Fittings WithSilicone Sealant.

Mount Sensor OutdoorsIn Shaded Protected

Area & In UprightPosition As Shown

OE331-21-VCMVCM Controller Board

Outdoor Air Temperature SensorThe Outdoor Air Sensor must be wired as shown in the illustration be-low for proper operation of the VCM controller. The Outdoor Air Tem-perature Sensor is a 10K Type III thermistor sensor. The sensor shouldbe mounted in the upright position as shown, in an area that is protectedfrom the elements and direct sunlight. Be sure to make the wiring splicesinside of the Outdoor Air Temperature Sensor weather-tight enclosure.See Figure 13 for detailed wiring.

Figure 13: Outdoor Air Temperature Sensor Wiring

Caution: Be sure to mount the Outdoor Air Sensor in anarea that is not exposed to direct sunlight. Theshaded area under the HVAC unit rain hood isnormally a good location. Unused conduitopening(s) must have closure plugs installedand must be coated with sealing compound toprovide a rain tight seal. Water can damagethe sensor.

Technical Guide

VCM Controller18

Figure 14: Economizer Damper Actuator Wiring

GND

AAONUnit

Terminals

INPUTS

GNDAOUT1

AOUT2

GND

+VDC

AIN1

AIN2

AIN3

AIN4

AIN5

AIN7

E

R

EC1

24 VAC Power SourceSized For Actuator VA Load

24

VA

C

GN

D

2-10 VDCOutput

Economizer Damper Actuator(Belimo Actuator Shown)

Y1 3Y1 3

+ 2+ 2

COM - 1COM - 1

OE331-21-VCMVCM Controller Board

Belimo Actuator WiringShown. Consult Factory ForOther Manufacturers Wiring

Instructions

Economizer Damper ActuatorThe Economizer Damper Actuator Signal voltage output is a 2-10 VDCoutput. This signal output is used by the VCM controller to modulatethe Economizer Damper Actuator in order to control the amount ofOutdoor Air delivered to the HVAC unit for Free Cooling and/or IndoorAir Quality requirements. See Figure 14 for detailed wiring.

Warning: It is very important to be certain that all wiring iscorrect as shown in the wiring diagram below.Failure to observe the correct polarity will result indamage to the actuator or VCM controller.

Input/Output Wiring Details

VCM Controller

Technical Guide

19

BK

RD

WHTransducer CableWith Built-In Signal

Conditioner

OE331-21-VCMVCM Controller Board

OE275-01-NDCSuction Pressure

Transducer

(250 PSIG)With Signal Conditioner

AIN5

GND

+VDC

Pullup Resistor PU5Must Be Removed

Suction Pressure TransducerThe Suction Pressure Transducer is required for any VCM applicationwith DX Cooling that requires Dehumidification. It is also required forany application which utilizes a digital scroll compressor.

The Suction Pressure Transducer is used to measure suction pressure atthe HVAC units DX evaporator coil suction line. This suction line pres-sure is converted to saturated refrigerant temperature by the VCM con-troller. This temperature is used by the VCM controller to accuratelycontrol the compressors and reheat cycle components to provide opti-mum performance from the system during Dehumidification operation.

When used in dehumidification applications on HVAC units withoutdigital scroll compressors the Suction Pressure Transducer wires to theVCM controller board as shown in Figure 15. In this application theSuction Pressure Transducer connects to the VCM board through a cablewith a built-in signal conditioner. The cable is supplied with a 3 pinPackard mating connector for attachment to the sensor on one end and

has 3 color coded stripped wires on the other end. The stripped wireends can be spliced to other wires to extend the wiring length whenrequired.

For applications that use a Digital Scroll Compressor, the Suction Pres-sure Transducer wires directly to the Digital Scroll Compressor Con-troller supplied by the compressor manufacturer. See Figure 16 forwiring details.

In this application the Suction Pressure Transducer connects to the digitalscroll compressor with a prefabricated cable similar to the one used inthe previous application but without the signal conditioner built in. Thesignal conditioning is controlled by the Digital Compressor controller.This cable also has a 3 pin Packard mating connector for attachment tothe sensor on one end and has 3 color coded stripped wires on the otherend. The stripped wire ends can be spliced to other wires to extend thewiring when required to connect the Digital Compressor controller.

Figure 15: Suction Pressure Transducer Wiring (Units Without Digital Compressors)

Technical Guide

VCM Controller20

Input/Output Wiring Details

Figure 16: Suction Pressure Transducer Wiring (Units With Digital Compressors)

OE

355

-4

An

alo

gO

utp

ut

Bo

ard

GND

AOUT2

1.5 to 5 VDC

24

VA

C

GN

D

OE352 or OE353 Expansion Base Board

OE331-21-VCMVCM Controller Board

10 VA Minimum Power Required ForEach 2 Slot Expansion Base Board.20 VA Minimum Power Required ForEach 4 Slot Expansion Base Board

WARNING!!Observe Polarity! All boards must be wired with GND-to-GND and 24VAC-to-24VAC. Failureto observe polarity will result in damage to one or more of the boards. Expansion Boardsmust be wired in such a way that power to both the expansion boards and the controller arealways powered together. Loss of power to the expansion board will cause the controller tobecome inoperative until power is restored to the expansion board.

GND

INPUTS

GND

AOUT1

AOUT2

GND

+VDC

AIN1

AIN2

AIN3

AIN4

AIN5

AIN7

Copeland DigitalCompressor Controller

P4

RD

WH

BK

P3

P2

P1

SHLD

EXC

OUT

COM

P5

P6

C1

C2

R20

C8

TB2

D3

PW

R

LD

1

24

VA

C-IN

GN

D

GN

D

TB1

PJ2

+2

4VD

C-O

UT

R1

7

PJ1

R1

5

Connect To VCM Controller

Connect ToNext Expansion Base Board

(When Used)

OE275-01-NDCSuction Pressure

Transducer(250 PSIG)

VCM Controller

Technical Guide

21

Supply Fan VFD Signal Or Zoning By-pass Damper ActuatorThe Supply Fan VFD or Zoning Bypass Damper Actuator Signal is a 0-10 VDCoutput. This signal output can be connected to the Supply Fan VariableFrequency Drive to modulate the Supply Fan speed and control DuctStatic Pressure utilizing the Duct Static Pressure Sensor connected tothe VCM controller board. Alternatively it can be connected to a Zon-ing Bypass Damper Actuator which will modulate the Zoning BypassDamper Actuator to control Duct Static Pressure utilizing the Duct StaticPressure Sensor connected to the VCM controller board. A Duct Static

+

Supply Fan Variable Frequency Drive(By Others)

_

VFD 0-10VDC Input

GND

Caution:The VFD Unit Must Be Configured For 0-10 VDC Input.The Input Resistance At The VFD Must Not Be LessThan 1000 Ohms When Measured At The VFDTerminals With All Input Wires Removed.

GND

INPUTS

GNDAOUT1

AOUT2

GND

+VDC

AIN1

AIN2

AIN3

AIN4

AIN5

AIN7

OE331-21-VCMVCM Controller Board

Bypass Damper Actuator(Belimo Actuator Shown)

0-10 VDC

24 VAC Power SourceSized For Actuator VA Load

GND

24 VAC

Y1 3Y1 3

+ 2+ 2

COM - 1COM - 1

GND

INPUTS

GNDAOUT1

AOUT2

GND

+VDC

AIN1

AIN2

AIN3

AIN4

AIN5

AIN7

OE331-21-VCMVCM Controller BoardBelimo Actuator Wiring

Shown. Consult Factory ForOther Manufacturers Wiring

Instructions

Pressure Sensor must be connected in order for the VFD or ZoningBypass Damper Actuator to operate. See Figure 17 and Figure 18 fordetailed wiring.

Caution: Variable Frequency Drive units can causelarge transient noise spikes which can causeinterference to be propagated on otherelectronic equipment. Use shielded wirewherever possible and route all sensor andcontroller wiring away from the VariableFrequency Drive and the HVAC Unit electrical

Figure 17: Supply Fan VFD Signal Wiring

Figure 18: Zoning Bypass Damper Signal Wiring

Technical Guide

VCM Controller22

Input/Output Wiring DetailsBinary Inputs WiringAll Binary Inputs are to be wired as 24 VAC wet contact closures. Only24 VAC power must be supplied to the OE356 Binary Input Boardthrough a Normally Open Contact closure in order for the signal to berecognized by the controller. If a Dry Contact closure is used , it willnot work. See Figure 19 for detailed wiring.

OE352 or OE353 Expansion Base Board

24

VA

C

GN

D

10 VA Minimum Power Required ForEach 2 Slot Expansion Base Board.20 VA Minimum Power Required ForEach 4 Slot Expansion Base Board

R20

C8

TB2

D3

PW

R

LD

1

24

VA

C-IN

GN

D

GN

D

TB1

PJ2

+2

4VD

C-O

UT

R1

7

PJ1

R1

5

Connect To VCM Controller

Connect To Next Expansion Base Board(When Used)

R4

R3

R2

R1

YS101788

BIN 4

BIN 3

BIN 2

BIN 1

COM

TB1

OPTO2

R10

R12

4 DIG. IN MOD. I/O BD.

P2

50

6-2

R8

R6

R5

P2

50

6-2

OPTO1

74

HC

14

N

PC

F8

57

4P

U2C4

C3

U1

CX2

C2

C1 CX1

P1

R4

R3

R2

R1

YS101788

BIN 4

BIN 3

BIN 2

BIN 1

COM

TB1

OPTO2

R10

R12

4 DIG. IN MOD. I/O BD.

P2

50

6-2

R8

R6

R5

P2

50

6-2

OPTO1

74

HC

14

N

PC

F8

57

4P

U2C4

C3

U1

CX2

C2

C1 CX1

P1

OE

35

6-4

Bin

ary

Inp

ut

Bo

ard

#1

OE

35

6-4

Bin

ary

Inp

ut

Bo

ard

#2Remote Forced Heating - N.O. Contact

Remote Forced Cooling - N.O. Contact

Exhaust Hood On - N.O. Contact

Dirty Filter - N.O. Contact

Proof Of Flow - N.O. Contact

Remote Forced Occupied - N.O. Contact

Smoke Detector - N.C. Contact

Remote Forced Dehumidification - N.O. Contact

COM

BIN4

BIN3

BIN2

BIN1

COM

BIN3

BIN4

BIN1

BIN2

WARNING!!Observe Polarity! All boards must be wired with GND-to-GND and 24VAC-to-24VAC. Failure to observepolarity will result in damage to one or more of the boards. Expansion Boards must be wired in such a way thatpower to both the expansion boards and the controller are always powered together. Loss of power to theexpansion board will cause the controller to become inoperative until power is restored to the expansion board.

Figure 19: Binary Inputs Wiring

Warning: Do not apply any voltage greater than 24 VAC tothe Binary Input Expansion boards. Higher voltageswill damage the expansion Board and possiblyother components on the system.

VCM Controller

Technical Guide

23

Outdoor Air Humidity SensorWhen used with the VCM controller, the Outdoor Air Humidity Sensoris connected to the system by wiring it to the AIN1 input on the OE354,4 Analog Input 1 Analog Output Expansion board. It must be wired asshown in Figure 20 for proper controller operation.

Jumpers Must Be Set asShown For CorrectO-5 VDC Operation

1 & 3 Are Off2 & 4 Are On

Jumpers Must Be Set asShown For Normal

1, 2, 4, 5 & 6 Are Off3 Is On

Operation Of Sensor

4-2

0m

A

Zero

Span

VA

Cor

DC

GN

D

0-5

Vo

r0

-10

V

4

4

4

5

5

6

6

ON

ON

ON

3

3

3

2

2

2

1

1

1

4

ON

3 2 1

24

VA

C

GN

D

OE352 or OE353 Expansion Base Board

OE265-13OA Humidity Sensor

10 VA Minimum Power Required ForEach 2 Slot Expansion Base Board.20 VA Minimum Power Required ForEach 4 Slot Expansion Base Board

R20

C8

TB2

D3

PW

R

LD

1

24

VA

C-IN

GN

D

GN

D

TB1

PJ2

+2

4VD

C-O

UT

R1

7

PJ1

R1

5

Connect To VCM Controller

Connect To Next Expansion Base Board(When Used)

0-5 VDC Input

OE

35

4-

4A

na

log

Inp

ut

-1

An

alo

gO

utp

ut

Bo

ard

GND

AIN1

JO3

JO4

JO2

JO1

CX

2

R10

AOUT1

AIN4

TB1

GND

AIN2

AIN3

AIN1

PU4

U2

D5

Q1

R8

R9

LM358

C5

C1

R7

R6

R5

PU3

C4

C3

C2

PU2

PU1

4 ANALOG IN MOD. I/O BD.

R3

YS101784

D4

R4

D3

D1

D2

R2

R1 CX1

U1

P1

Pullup Resistor PU1 MustBe Removed As Shown

Jumper J01 MustBe Removed As Shown

WARNING!!Observe Polarity! All boards must be wired with GND-to-GND and 24VAC-to-24VAC. Failure to observe polarity willresult in damage to one or more of the boards. ExpansionBoards must be wired in such a way that power to both theexpansion boards and the controller are always poweredtogether. Loss of power to the expansion board will causethe controller to become inoperative until power is restoredto the expansion board.

Warning: It is very important to be certain that all wiring iscorrect as shown in the wiring diagram below.Failure to observe the correct polarity willresult in damage to the OA Humidity Sensor orcontroller.

Figure 20: Outdoor Air Humidity Sensor Wiring

Technical Guide

VCM Controller24

Indoor Wall Mounted Humidity SensorWhen used with the VCM controller, the Indoor Wall Mounted Humid-ity Sensor is connected to the system by wiring it to the AIN2 input onthe OE354, 4 Analog Input, 1 Analog Output Expansion board. It mustbe wired as shown in Figure 21 for proper controller operation.

24

VA

C

GN

D

10 VA Minimum Power Required ForEach 2 Slot Expansion Base Board.20 VA Minimum Power Required ForEach 4 Slot Expansion Base Board

R20

C8

TB2

D3

PW

R

LD

1

24

VA

C-IN

GN

D

GN

D

TB1

PJ2

+2

4VD

C-O

UT

R1

7

PJ1

R1

5

Connect To VCM Controller

Connect To Next Expansion Base Board(When Used)

OE

35

4-

4A

na

log

Inp

ut

-1

An

alo

gO

utp

ut

Bo

ard

GND

AIN2

0-5 VDC Input

Jumpers Must Be Set asShown For CorrectO-5 VDC Operation

1 & 3 Are Off2 & 4 Are On

Jumpers Must Be Set asShown For Normal

1, 2, 4, 5 & 6 Are Off3 Is On

Operation Of Sensor

Vo

Zero Span

Gnd

Vin

Io

4

44

4

5

5

6

6

ON

ON

ON

ON

3

33

3

2

22

2

1

11

1

JO3

JO4

JO2

JO1

CX

2

R10

AOUT1

AIN4

TB1

GND

AIN2

AIN3

AIN1

PU4

U2

D5

Q1

R8

R9

LM358

C5

C1

R7

R6

R5

PU3

C4

C3

C2

PU2

PU1

4 ANALOG IN MOD. I/O BD.

R3

YS101784

D4

R4

D3

D1

D2

R2

R1 CX1

U1

P1

Pullup Resistor PU2 MustBe Removed As Shown

Jumper J02 MustBe Removed As Shown

OE352 or OE353 Expansion Base Board

OE265-11Space Humidity Sensor

WARNING!!Observe Polarity! All boards must be wired with GND-to-GND and 24VAC-to-24VAC. Failure to observe polarity willresult in damage to one or more of the boards. ExpansionBoards must be wired in such a way that power to both theexpansion boards and the controller are always poweredtogether. Loss of power to the expansion board will causethe controller to become inoperative until power is restoredto the expansion board.

Warning: It is very important to be certain that all wiringis correct as shown in the wiring diagram below.Failure to observe the correct polarity will result indamage to the Space Humidity Sensor orcontroller.

Figure 21: Indoor Wall Mounted Humidity Sensor Wiring

Input/Output Wiring Details

VCM Controller

Technical Guide

25

Return Air Mounted Humidity SensorWhen used with the VCM controller, the Return Air Mounted Humid-ity Sensor is connected to the system by wiring it to the AIN2 input onthe OE354, 4 Analog Input, 1 Analog Output Expansion board. It mustbe wired as shown in Figure 221 for proper controller operation.

Jumpers Must Be Set asShown For CorrectO-5 VDC Operation

1 & 3 Are Off2 & 4 Are On

Jumpers Must Be Set asShown For Normal

1, 2, 4, 5 & 6 Are Off3 Is On

Operation Of Sensor

4

4

4

5

5

6

6

ON

ON

ON

3

3

3

2

2

2

1

1

1

4

ON

3 2 1

24

VA

C

GN

D

10 VA Minimum Power Required ForEach 2 Slot Expansion Base Board.20 VA Minimum Power Required ForEach 4 Slot Expansion Base Board

R20

C8

TB2

D3

PW

R

LD

1

24

VA

C-IN

GN

D

GN

D

TB1

PJ2

+2

4VD

C-O

UT

R1

7

PJ1

R1

5

Connect To VCM Controller

Connect To Next Expansion Base Board(When Used)

OE

354

-4

Analo

gIn

put-

1A

nalo

gO

utp

utB

oard

GND

AIN2

0-5 VDC InputJO3

JO4

JO2

JO1

CX

2

R10

AOUT1

AIN4

TB1

GND

AIN2

AIN3

AIN1

PU4

U2

D5

Q1

R8

R9

LM358

C5

C1

R7

R6

R5

PU3

C4

C3

C2

PU2

PU1

4 ANALOG IN MOD. I/O BD.

R3

YS101784

D4

R4

D3

D1

D2

R2

R1 CX1

U1

P1

Pullup Resistor PU2 MustBe Removed As Shown

Jumper J02 MustBe Removed As Shown

OE352 or OE353 Expansion Base Board

OE265-14RA Humidity Sensor

WARNING!!Observe Polarity! All boards must be wired with GND-to-GND and 24VAC-to-24VAC. Failure to observe polarity willresult in damage to one or more of the boards. ExpansionBoards must be wired in such a way that power to both theexpansion boards and the controller are always poweredtogether. Loss of power to the expansion board will causethe controller to become inoperative until power is restoredto the expansion board.

4-2

0m

A

Zero

Span

VA

Cor

DC

GN

D

0-5

Vo

r0

-10

V

Warning: It is very important to be certain that all wiringis correct as shown in the wiring diagram below.Failure to observe the correct polarity will result indamage to the RA Humidity Sensor or controller.

Figure 22: Indoor Return Air Mounted Humidity Sensor Wiring

Technical Guide

VCM Controller26

Building Pressure Sensor WiringThe OE258 Building Pressure Sensor must be wired as shown in theillustration below for proper operation. There are 3 terminal connec-tions on the OE258 Building Pressure Sensor. Connect the power sideof the 24 VAC power source to the terminal labeled “+ EXC” . Connectthe GND side of the 24 VAC power source to the terminal labeled “-COM”. Connect the remaining terminal labeled “OUT” to AIN4 on theOE354, 4 Analog Output 1 Analog Input Expansion Board terminalblock. See Figure 23 below for detailed wiring. The pullup resistor P4on the expansion board must be removed and the voltage jumper J04

24

VA

C

GN

D

10 VA Minimum Power Required ForEach 2 Slot Expansion Base Board.20 VA Minimum Power Required ForEach 4 Slot Expansion Base Board

R20

C8

TB2

D3

PW

R

LD

1

24

VA

C-IN

GN

D

GN

D

TB1

PJ2

+2

4VD

C-O

UT

R1

7

PJ1

R1

5

Connect To VCM Controller

Connect To Next Expansion Base Board(When Used)

OE

35

4-

4A

na

log

Inp

ut

Bo

ard

-1

An

alo

gO

utp

ut

Bo

ard

GND

AIN4EXC

COM

OUT 0-5 VDC Input

HIG

H

LO

W

-+

+ +

Tubing To BuildingPressure Sensing Location

Tubing To AtmosphericPressure Sensing Location

-

+ JO3

JO4

JO2

JO1

CX

2

R10

AOUT1

AIN4

TB1

GND

AIN2

AIN3

AIN1

PU4

U2

D5

Q1

R8

R9

LM358

C5

C1

R7

R6

R5

PU3

C4

C3

C2

PU2

PU1

4 ANALOG IN MOD. I/O BD.

R3

PC

F8

59

1P

YS101784

D4

R4

D3

D1

D2

R2

R1

PHILIPS

T L

HA

AN

I D

CX1

U1

P1

Pullup Resistor PU4 MustBe Removed As Shown

Jumper J04 MustBe Removed As Shown

OE352 or OE353 Expansion Base Board

OE258Building Pressure Sensor

WARNING!!Observe Polarity! All boards must be wired with GND-to-GND and 24VAC-to-24VAC. Failure to observe polarity willresult in damage to one or more of the boards. ExpansionBoards must be wired in such a way that power to both theexpansion boards and the controller are always poweredtogether. Loss of power to the expansion board will causethe controller to become inoperative until power is restoredto the expansion board.

must also be removed as shown in the wiring diagram for the OE258Building Pressure Sensor to operate correctly.

Warning: It is very important to be certain that all wiringis correct as shown in the wiring diagram below.Failure to observe the correct polarity will resultin damage to the HVAC Unit Controller, BuildingPressure Sensor and the Expansion Board.

Figure 23: Building Pressure Sensor Wiring

Input/Output Wiring Details

VCM Controller

Technical Guide

27

Building Pressure ControlOutput WiringThe Building Pressure Control Output is a 0-10 VDC or 2-10 VDCsignal sent from the OE354, 4 Analog Input 1 Analog Output Expan-sion Board. When using the output for Direct Building Pressure control(output signal rises on a rise in building pressure), the output signal canbe connected to either a Variable Frequency Drive controlling an ex-haust fan or to a damper actuator controlling an exhaust damper. Whenused in this manner the output signal must be configured for DirectActing operation.

When using this output for Reverse Building Pressure Control (outputsignal rises on a fall in building pressure), a damper actuator control-ling an OA Damper would be used. When using the OA damper forReverse Building Pressure Control, the output signal must be config-ured for Reverse Acting operation. A Building Pressure Sensor con-

24

VA

C

GN

D

10 VA Minimum Power Required ForEach 2 Slot Expansion Base Board.20 VA Minimum Power Required ForEach 4 Slot Expansion Base Board

R20

C8

TB2

D3

PW

R

LD

1

24

VA

C-IN

GN

D

GN

D

TB1

PJ2

+2

4VD

C-O

UT

R1

7

PJ1

R1

5

Connect To VCM Controller

Connect To Next Expansion Base Board(When Used)

OE

35

4-

4A

na

log

Inp

ut

-1

An

alo

gO

utp

ut

Bo

ard

GND

AOUT1

JO3

JO4

JO2

JO1

CX

2

R10

AOUT1

AIN4

TB1

GND

AIN2

AIN3

AIN1

PU4

U2

D5

Q1

R8

R9

LM358

C5

C1

R7

R6

R5

PU3

C4

C3

C2

PU2

PU1

4 ANALOG IN MOD. I/O BD.

R3

PC

F8

59

1P

YS101784

D4

R4

D3

D1

D2

R2

R1

PHILIPS

T L

HA

AN

I D

CX1

U1

P1

+

Building Pressure ControlExhaust Fan Variable Frequency Drive

(By Others)

_

0-10VDC or 2-10 VDC(Configurable)

GND

The VFD Unit Must Be Configured For 0-10vdc Input. TheInput Resistance At The VFD Must Not Be Less Than 1000Ohms When Measured At The VFD Terminals With AllInput Wires Removed.

WARNING!!Observe Polarity! All boards must be wired with GND-to-GND and 24VAC-to-24VAC. Failure to observe polarity willresult in damage to one or more of the boards. ExpansionBoards must be wired in such a way that power to both theexpansion boards and the controller are always poweredtogether. Loss of power to the expansion board will causethe controller to become inoperative until power is restoredto the expansion board.

OE352 or OE353 Expansion Base Board

Building Pressure ControlDamper Actuator

(By Others - Belimo Actuator Shown)

Wiring When Using Damper ActuatorFor Building Pressure Control

Both Types Of Building Pressure ControlDevices Are Shown

Only One Type Of Building Pressure ControlDevice May Be Used On Each HVAC Unit

Wiring When Using Exhaust Fan VFDFor Building Pressure Control

GND

24 VAC

Y1 3Y1 3

+ 2+ 2

COM - 1COM - 1

Belimo Actuator WiringShown. Consult Factory ForOther Manufacturers Wiring

Instructions

nected to AIN4 on the OE354 Expansion board is used to sense andcontrol the signal to the Building Pressure Output. The OE258 Build-ing Pressure Sensor must be connected in order for the Building Pres-sure Output to operate correctly.

See Figure 24 for detailed wiring of the Building Pressure ControlOutput Signal.

Caution: Variable Frequency Drive units can cause largetransient noise spikes which can causeinterference to be propagated on otherelectronic equipment. Use shielded wirewherever possible and route all sensor andcontroller wiring away from the VariableFrequency Drive and the HVAC unit electricalwiring.

Figure 24: Building Pressure Control Output Wiring

Technical Guide

VCM Controller28

CO2 Sensor Wiring

The OE255 or OE256 CO2 Sensors are used to sense the current CO

2

level in the conditioned space. The pullup resistor PU3 must be re-moved and the voltage jumper J03 must be in position (0-10 VDC posi-tion ) on the OE354, 4 Analog Input 1 Analog Output Expansion Boardfor proper operation of the CO

2 Sensor. See Figure 25 for detailed wir-

ing.2

4V

AC

GN

D

10 VA Minimum Power Required ForEach 2 Slot Expansion Base Board.20 VA Minimum Power Required ForEach 4 Slot Expansion Base Board

R20

C8

TB2

D3

PW

R

LD

1

24

VA

C-IN

GN

D

GN

D

TB1

PJ2

+2

4VD

C-O

UT

R1

7

PJ1

R1

5

Connect To VCM Controller

Connect To Next Expansion Base Board(When Used)

OE

354

-4

Analo

gIn

put-1

Analo

gO

utp

utB

oard

GND

AIN3

0-10 VDC InputJO3

JO4

JO2

JO1

CX

2

R10

AOUT1

AIN4

TB1

GND

AIN2

AIN3

AIN1

PU4

U2

D5

Q1

R8

R9

LM358

C5

C1

R7

R6

R5

PU3

C4

C3

C2

PU2

PU1

4 ANALOG IN MOD. I/O BD.

R3

PC

F8

59

1P

YS101784

D4

R4

D3

D1

D2

R2

R1 CX1

U1

P1

OE255 or OE256CO Sensor

(0-10VDC Signal)2

1.-

NotU

sed

2.-

NotU

sed

4.R

ela

yC

om

mon

5.R

ela

yN

orm

Clo

sed

6.

4-2

0m

AO

utp

ut

3.R

ela

yN

orm

Open

7.

Sig

na

lG

rou

nd

8.

0-1

0V

Ou

tpu

t

Pin

Desig

natio

ns

Pin

Desig

natio

ns

1.

AC

+/D

C+

2.

AC

/GN

D

Pullup Resistor PU3 MustBe Removed As Shown

Jumper J03 MustBe In Place As Shown

OE352 or OE353 Expansion Base Board

WARNING!!Observe Polarity! All boards must be wired with GND-to-GND and 24VAC-to-24VAC. Failure to observe polarity willresult in damage to one or more of the boards. ExpansionBoards must be wired in such a way that power to both theexpansion boards and the controller are always poweredtogether. Loss of power to the expansion board will causethe controller to become inoperative until power is restoredto the expansion board.

Input/Output Wiring Details

Warning: It is extremely important to be certain that theCO

2 Sensors “AC/GND” terminal is connected to

the GND terminal on the OE354 expansion boardand to the 24 VAC expansion base board powersource GND connection. The “AC+/DC+ ”terminal on the CO

2 Sensor must be connected to

the 24 VAC power side of the 24 VAC powersource supplying power to the expansion baseboard terminal as shown. Failure to observe thecorrect polarity will result in damage to the HVACUnit Controller, CO

2 Sensor and the Expansion

Board.

Figure 25: CO2 Sensor Wiring

VCM Controller

Technical Guide

29

Modulating Heating Device WiringThe Modulating Heating Device signal can be configured for either a0-10 VDC or 2-10 VDC output signal. The output signal can be config-ured for either Direct Acting or Reverse Acting operation as required.

The Output signal is normally used to control a Modulating Hot WaterValve, Modulating Steam Valve or for SCR Control of an Electric Heat-ing Coil.

See Figure 26 for detailed wiring of the Modulating Heating Device.24

VA

C

GN

D

10 VA Minimum Power Required ForEach 2 Slot Expansion Base Board.20 VA Minimum Power Required ForEach 4 Slot Expansion Base Board

R20

C8

TB2

D3

PW

R

LD

1

24

VA

C-IN

GN

D

GN

D

TB1

PJ2

+2

4VD

C-O

UT

R1

7

PJ1

R1

5

Connect To VCM Controller

Connect To Next Expansion Board(When Used)

GND

AOUT1+

Modulating Heating Device(By Others)

_

0-10 VDC or 2-10 VDC(Configurable)

GND

The Modulating Heating Device Used Must Be Designed ToAccept Either a 0-10 Or a 2-10 VDC Input. The AOUT1Output Voltage Is User Configurable For Either Voltage. TheHeating Device Used Can Be A Modulating Hot Water Valve,Steam Valve Or SCR Controlled Electric Heating Coil.

OE

35

5-

4A

na

log

Ou

tpu

tB

oa

rd

OE352 or OE353 Expansion Base Board

WARNING!!Observe Polarity! All boards must be wired with GND-to-GND and 24VAC-to-24VAC. Failure to observe polarity willresult in damage to one or more of the boards. ExpansionBoards must be wired in such a way that power to both theexpansion boards and the controller are always poweredtogether. Loss of power to the expansion board will causethe controller to become inoperative until power is restoredto the expansion board.

GND

AOUT1

YS1017864 AOUT MOD. I/O BD.

CX1

U1

Q1

LM

35

8

R2 U2

R9

D1

R6

D2

R7

D4

D3

R8

TB

1

CX2

C3

C1

P1

RV

1

R1

C4 U3

C2

LM

35

8

CX3

AOUT2

AOUT3

AOUT4

Q2

R3

Q4

Q3

R4

R5

Warning: It is very important to be certain that all wiring iscorrect as shown in the wiring diagram below.Failure to observe the correct polarity couldresult in damage to the Modulating Heating Deviceor the Analog Output expansion board.

Figure 26: Modulating Heating Device Wiring

Technical Guide

VCM Controller30

Modulating Cooling Device WiringThe Modulating Cooling Device signal can be configured for either a0-10 VDC, 2-10 VDC or 1.5-5.0 VDC output signal. The output signalcan also be configured for either Direct Acting or Reverse Acting op-eration as required by your application. This signal output would nor-mally be connected to a Modulating Chilled Water Valve or DigitalCompressor Controller.

See Figure 27 for detailed wiring of the Modulating Cooling Devicewhen using a Chilled Water Valve. When this output is used with aDigital Compressor, the Suction Line Pressure Transducer must be wired

24

VA

C

GN

D

10 VA Minimum Power Required ForEach 2 Slot Expansion Base Board.20 VA Minimum Power Required ForEach 4 Slot Expansion Base Board

R20

C8

TB2

D3

PW

R

LD

1

24

VA

C-IN

GN

D

GN

D

TB1

PJ2

+2

4VD

C-O

UT

R1

7

PJ1

R1

5

Connect To VCM Controller

Connect To Next Expansion Board(When Used)

GND

AOUT2+

Modulating Cooling Device(By Others)

_ GND

OE

355

-4

Analo

gO

utp

utB

oard

OE352 or OE353 Expansion Base Board

WARNING!!Observe Polarity! All boards must be wired with GND-to-GND and 24VAC-to-24VAC. Failure to observe polarity willresult in damage to one or more of the boards. ExpansionBoards must be wired in such a way that power to both theexpansion boards and the controller are always poweredtogether. Loss of power to the expansion board will causethe controller to become inoperative until power is restoredto the expansion board.

0-10 VDC, 2-10 VDC or 1.5-5.0 VDC(Configurable)

The Modulating Cooling Device Used Must Be DesignedTo Accept Either A 0-10 VDC, 2-10 VDC Or 1.5-5.0 VDCInput. The AOUT1 Output Voltage Is User ConfigurableFor These Voltages. The Cooling Device Used Can Be AModulating Chilled Water Valve or A Digital ScrollCompressor. If Using A Digital Scroll CompressorPlease See Digital Scroll Detailed Information InThis Manual.

Wiring

GND

AOUT1

YS1017864 AOUT MOD. I/O BD.

CX1

U1

Q1

LM

358

R2 U2

R9

D1

R6

D2

R7

D4

D3

R8

TB

1

CX2

C3

C1

P1

RV

1

R1

C4 U3

C2

LM

358

CX3

AOUT2

AOUT3

AOUT4

Q2

R3

Q4

Q3

R4

R5

to the Digital Compressor Controller instead of the VCM board and theModulating Cooling Output signal must be configured for a 1.5 to 5.0VDC output signal. For Digital Compressor wiring detailssee Figure 16.

Warning: It is very important to be certain that all wiringis correct as shown in the wiring diagrambelow. Failure to observe the correct polarity couldresult in damage to the Modulating Cooling Device.

Figure 27: Modulating Cooling Device Wiring

Input/Output Wiring Details

VCM Controller

Technical Guide

31

Return Air Bypass WiringThe VCM controller can be configured for PAC or DPAC controlschemes. Both PAC and DPAC control schemes provide improved mois-ture removal capabilities while utilizing internal space loads for reheatby redirecting the Return Air around the Evaporator Coil instead ofthrough the coil. See the PAC and DPAC applications section of thismanual for complete operation details.

The PAC & DPAC control schemes both utilize a Return Air BypassDamper Actuator and a Return Air Damper Actuator to modulate theReturn Air and Return Air Bypass Dampers to control the amount ofair that is redirected around the Evaporator Coil.

The DPAC control scheme provides improved moisture removal ca-pabilities and tighter temperature control than the PAC controls schemeby combining Digital Compressor control in addition to Return AirBypass control.

See Figure 28 for detailed wiring of the Return Air Bypass and ReturnAir Damper Actuators.

See Figure 16 for detailed wiring of the Digital Compressor.

Warning: It is very important to be certain that all wiring iscorrect as shown in the wiring diagram below.Failure to observe the correct polarity couldresult in damage to the Damper Actuators or theAnalog Output expansion board.

Figure 28: Return Air Bypass Wiring

24

VA

C

GN

D

10 VA Minimum Power Required ForEach 2 Slot Expansion Base Board.20 VA Minimum Power Required ForEach 4 Slot Expansion Base Board

R20

C8

TB2

D3

PW

R

LD

1

24

VA

C-IN

GN

D

GN

D

TB1

PJ2

+2

4VD

C-O

UT

R1

7

PJ1

R1

5

Connect To VCM Controller

Connect To Next Expansion Board(When Used)

GND

AOUT4

AOUT3

0-10 VDC

0-10 VDC

GND

OE

35

5-

4A

na

log

Ou

tpu

tB

oa

rd

OE352 or OE353 Expansion Base Board

WARNING!!Observe Polarity! All boards must be wired with GND-to-GND and 24VAC-to-24VAC. Failure to observe polarity willresult in damage to one or more of the boards. ExpansionBoards must be wired in such a way that power to both theexpansion boards and the controller are always poweredtogether. Loss of power to the expansion board will causethe controller to become inoperative until power is restoredto the expansion board.

GND

AOUT1

YS1017864 AOUT MOD. I/O BD.

CX1

U1

Q1

LM

35

8

R2 U2

R9

D1

R6

D2

R7

D4

D3

R8

TB

1

CX2

C3

C1

P1

RV

1

R1

C4 U3

C2

LM

35

8

CX3

AOUT2

AOUT3

AOUT4

Q2

R3

Q4

Q3

R4

R5

Return Air BypassDamper Actuator

(0-10 VDC)

Return AirDamper Actuator

(0-10 VDC)

Belimo Actuator WiringShown. Consult Factory ForOther Manufacturers Wiring

Instructions

Y1 3

Y1 3

+ 2

+ 2

COM 1

COM 1

Technical Guide

VCM Controller32

Start-up & CommissioningIn order to have a trouble free start-up it is important to follow a fewsimple procedures. Before applying power for the first time it is veryimportant to correctly address the controller and run through a few simplechecks.

Controller AddressingAll VCM controllers are equipped with address switches. If the VCMcontroller is to operate as a stand alone system (not connected to anyother HVAC unit or VAV/Zone controllers) the controller address switchshould be set for address 1. When using the Modular Service Tool orSystem Manager to program and configure the VCM controller youwould enter this address to communicate with the controller. When thesystem is to be connected to other HVAC unit controllers on a commu-nication loop, each controllers address switch must be set with a uniqueaddress between 1 and 59. When the VCM controller will be used withVAV/Zone controllers the VCM controller’s address switch must be setas address 59, no exception. See Figure 29 for address switch settinginformation. For detailed information regarding communication wiringand connection for interconnected and networked systems, please seethe Orion System Installation & Troubleshooting Guide.

Power WiringOne of the most important checks to make before powering up the sys-tem for the first time, is to confirm proper voltage and transformer siz-ing for the controller. Each VCM controller requires 8 VA of powerdelivered to it at 24 VAC. Each 2 slot expansion board requires 10 VA

at 24 VAC and each 4 slot expansion board requires 20 VA at 24 VAC.You may use separate transformers for each device (preferred) or powerseveral devices from a common transformer. If several devices are to bepowered from a single transformer correct polarity must be followed.

Warning: Observe Polarity! All boards must be wired withGND-to-GND and 24 VAC-to-24 VAC. Failure toobserve polarity will result in damage to one ormore of the boards. Expansion Boards must bewired in such a way that the Expansion Boards andthe VCM Controller are always powered together.Loss of power to the Expansion Board will causeit to become inoperative until power is restored tothe Expansion Board.

Check all wiring leads at the terminal block for tightness. Be sure thatwire strands do not stick out and touch adjacent terminals. Confirm thatall sensors required for your system are mounted in the appropriatelocation and wired into the correct terminals on the VCM controller. Besure any Expansion Boards connected to the VCM controller are alsocorrectly wired just as you did for the VCM controller.

After all the above wiring checks are complete, apply power to theVCM controller and all expansion boards connected to it.

4

NETWORK

TOKEN

16

32

8

SW1

ADD

2

1

ADDRESS

V6

PO

WE

R

GND

24VAC

L1

D1

6

R6

C9

SC1

R11

U11

D1

3

C16

VR2

TB4

R2

7

C13

R1

0

VR1

C1

9

C1

8

R7

D1

0

R13D12

C7CX10

U10

CX12

U12

U14

CX14

PJ3

PJ2

PJ1

EXPANSION

PRESSURESENSOR

C17D15

R26

C20 R25

R24

R22

U15

CX13

U13

C15

R19

R15

C14

D1

8

D1

7

PU1

PU2

PU3

PU4

PU5

PU7

D6

D7

D8

D9

D11

D14

C12

C10 0-5

VD

C

0-1

VD

C

JP1

C11

X2

GNDTB3

INPUTS

GND

GND

+VDC

AIN1

AIN2

AIN3

AIN4

AIN5

AOUT1

AOUT2

AIN7

RN5

D19

CX15

1632TOKEN

NETWORK

8421

Address Switch Shown IsSet For Address 1

Address Switch Shown IsSet For Address 13

ControllerAddress Switch

This Switch Should BeIn The OFF PositionAs Shown

Note:The Power To The Controller Must Be Removed AndReconnected After Changing The Address Switch Settings

CautionDisconnect All Communication Loop Wiring From TheController Before Removing Power From The Controller.Reconnect Power And Then Reconnect Communication LoopWiring.

ADDRESS ADD

ADDRESSADD

ADDRESSADD

The Address For Each ControllerMust Be Unique To The Other Controllers

On The Local Loop And Be Between 1 and 59

Figure 29: VCM Controller Address Switch Setting

VCM Controller

Technical Guide

33

Initialization:On system power up a 30 second startup delay is performed where alldefault setpoints are initialized, LED’s are initialized and all outputsare turned off.

When power is first applied, LED 1 and LED2 will flash out the con-troller address. LED1 will flash to represent Tens. LED2 will flash torepresent Ones. After the controller address is complete, there will be ashort pause and then 60 fast flashes to represent controller initializa-tion. There will be no controller operation or communications duringinitialization. After initialization, LED1 & LED2 will continuously flashthe status code.

Example of a controller address of 59:LED1 will flash 5 times. LED2 will flash 9 times.

See Table 2 in the Troubleshooting Section of this manual for detaileddiagnostic blink code information.

Operating SummaryThere is a standard set of operating instructions that are continuouslyrepeated during normal operations. They are listed below.

1.) Read Analog Inputs for Temperatures, Pressures and BinaryContact Closures

2.) Calculate Occupied / Unoccupied Mode of Operation

3.) Calculate HVAC Mode of Operation

4.) Set all outputs to match calculations for Heating or Coolingor vent Mode

5.) Broadcast information to other controllers if configured.

6.) Log all temperatures and output conditions

7.) Repeat steps 1 through 6 continuously

Programming The ControllerThe next step is programming the controller for your specific require-ments. In order to configure and program the VCM controller you mustuse an operator interface. Four different operator interfaces are avail-able for programming and monitoring of the VCM controller. Theseare:

• Modular Service Tool

• Modular System Manager

• Tactio SI Touch Screen Interface

• Notebook or Desktop Computer WithPrism II Computer Front End Software Installed

Any of these devices or a combination of them can be used to access thestatus, configuration and setpoints of any controller on your communi-cations loop. See the Operator Interfaces Technical Guide for completeVCM controller programming instructions if you are going to be usingthe Modular Service Tool or Modular System Manager with your sys-tem.

If you are going to be using a Notebook or Desktop computer and thePrism II Computer Front End Software, please see the Orion Prism IIComputer Front End Technical Guide. If you will be using the Tactio SIInterface please see the Tactio SI Touch Screen Technical Guide. Nomatter which operator interface you use, it is recommended that youproceed with the programming and setup of the VCM controller in theorder that follows:

1.) Configure The Controller For Your Application

2.) Program The Controller Setpoints.

3.) Program The Controller Operation Schedules.

4.) Set The Controller Current Time And Date.

5.) Review Controller Status Screens To Verify SystemOperation And Correct Controller Configuration

Figure 30: Modular Service Tool & Modular System Manager Operator Interfaces

ENTER

CLEARESC

PREV NEXT

DOWN

UP

654

DEC

7

0

8

1 32

9

MINUS-

STATUS

SETPOINTS

SCHEDULES

ALARMS

OVERRIDES

System Manager

Mode

Selection

ENTER

CLEARESC

PREV NEXT

DOWN

UP

654

DEC

7

0

8

1 32

9

MINUS-

STATUS

SETPOINTS

SCHEDULES

CONFIGURATION

ALARMS

ON

OVERRIDES

BALANCE - TEST

Technical Guide

VCM Controller34

Inputs & OutputsVCM ControllerAIN1 - Space Temperature Sensor InputIf you want to generate Occupied or Unoccupied Heating and Coolingdemands based on Space Temperature, select this Sensor for the HVACMode enable. The Space Temperature Sensor can be used for NightSetback control regardless of the HVAC Mode Sensor selected. If theSpace Temperature Sensor used is equipped with the optional Push-button Override Feature, this input will detect user overrides from Un-occupied back to Occupied operation for a user adjustable amount oftime. This Sensor is not required for Cooling Only HVAC units config-ured for Supply Air Temperature control as the HVAC Mode EnableSensor, unless Night Setback operation is required. The Space Tem-perature can also be configured to reset the Supply Air TemperatureSetpoint. The Space Temperature Sensor is the only Sensor that can beused for Night Setback operation during the Unoccupied Mode.

AIN2 - Supply Air Temperature Sensor InputThe Supply Air Temperature Sensor is the default HVAC Mode EnableSensor. For typical VAV units that are Cooling Only with Morning Warm-up, this Sensor should be configured as the HVAC Mode Enable Sen-sor. Heating will only occur during Morning Warm-up. After MorningWarm-up expires, the Supply Air Temperature will be maintained at theSupply Air Temperature Cooling Setpoint. The HVAC unit must al-ways have a Supply Air Temperature Sensor installed.

AIN3 - Return Air Temperature Sensor InputIf you want to generate occupied Heating and Cooling demands basedon Return Air Temperature, select this Sensor as the HVAC Mode En-able Sensor. The Return Air Temperature Sensor is also used to initiateor cancel the Morning Warm-up Period. This temperature must be atleast 5°F above the Outdoor Air Temperature to allow Economizer-Cooling operation.

AIN4 - Outdoor Air Temperature Sensor InputThe Outdoor Air Temperature is used to lockout Heating or Cooling toconserve energy at whatever temperature the user deems appropriatefor each Mode of operation. The Outdoor Air Temperature Sensor canalso be used to provide Low Ambient Temperature Protection in thebuilding. If the Outdoor Air Temperature is below the Low AmbientTemperature Setpoint, the Preheat Relay Output will be maintained dur-ing Occupied operation and will not be allowed to stage off unless theSupply Fan is turned off. When using 100% (MUA Units) Outdoor Airapplications, the Outdoor Air Temperature Sensor should be config-ured as the HVAC Mode Enable Sensor. The Outdoor Air TemperatureSensor is also used in combination with the Outdoor Air Humidity Sen-sor for Dewpoint calculations.

AIN5 – Suction Pressure Sensor InputA Suction Pressure Sensor can be connected to this input. This Sensoris required when using Dehumidification with DX Cooling units. TheVCM controller converts the Suction Pressure reading to Suction Tem-perature. This calculated Evaporator Coil Temperature, is considered tobe the Saturation Vapor Pressure of the refrigerant leaving the evapora-tor coil. In most cases, the Supply Air Temperature leaving the Evapo-rator coil will be 10°F to 15°F higher than the calculated EvaporatorCoil Temperature.

Note: All temperature Sensors must be Thermistor Type IIIwhich provide 77.0°F @ 10 K Ohms Resistance.

AIN6 - Duct Static Pressure Sensor InputThis special phone jack style input connection accepts a Duct StaticPressure Sensor input modular cable. The Duct Static Pressure Sensorreading is used to determine current Duct Static Pressure. This StaticPressure reading is used to control the output signal supplied to theSupply Fan VFD or Zoning Bypass Damper Actuator. If you have con-figured the HVAC unit for Constant Volume operation, this Sensor isoptional. If it is installed on a Constant Volume unit, it will not affectoperation, it will be used as a status only reading.

AIN7 – Space Temp. Sensor Slide Adjust orRemote SAT Reset Signal InputAIN 7 on the VCM controller is a dual purpose input. It can be used forthe Space Sensor Slide Adjust option or for connection of the RemoteSupply Air Setpoint Reset Signal option. Only one or the other can beused not both.

Space Temperature Sensor Slide AdjustIf the Space Temperature Sensor being used has the optional Slide Ad-just feature, its AUX output is connected to this input. The Slide Adjustcontrol is used to vary the HVAC Mode Heating and Cooling Setpointsby a user configured maximum amount. The Slide Adjustment adjustswhichever Temperature Sensor that has been configured as the HVACMode Enable Sensor even if that Sensor is not the installed Space Tem-perature Sensor.

If Space Temperature is configured as the SAT/Reset Source, the SlideAdjustment adjusts both the HVAC Mode Enable Heating and Coolingsetpoints and the SAT/Reset Source Heating and Cooling setpoints si-multaneously by a user configurable maximum amount.

Remote Supply Air Temperature Reset SignalWhen a 0-5 VDC Remote Supply Air Temperature Reset Signal is to beused, the controller must be configured for it and the Room SensorSlide Offset setpoint must be set to zero for this option. If the slideoffset is not set to zero, the Supply Air Temperature Reset will not func-tion.

The Remote Supply Air Temperature Reset signal must be configuredso its setpoint will be at the coldest Supply Air Temperature at 0 VDCand its setpoint will be at the warmest Supply Air Temperature at 5VDC.

If a 0-10 VDC reset signal is used, a resistor network will need to beinstalled on AIN 7. See the VCM wiring diagram for details.

AOUT1 - Economizer Control SignalThis voltage signal (2-10 VDC) is used to position the Outdoor AirDamper during Economizer Control. It is also used to maintain theOutdoor Air Damper at its Minimum Position during the Occupied Modewhen the Outdoor Air Temperature and/or Outdoor Humidity is notsuitable for Economizer Cooling purposes.

VCM Controller

Technical Guide

35

AOUT2 - Duct Static Pressure Control SignalThis voltage signal (0-10 VDC) can be connected to a Supply Fan VFDor to Proportional Inlet Vanes to control the Duct Static Pressure. Thissignal can also be connected to a 0-10 VDC Modulating Zoning BypassDamper Actuator to control Duct Static Pressure. When this signal isused to control a Zoning Bypass Damper Actuator, the Zoning BypassDamper Actuator needs to be mechanically configured to close the Zon-ing Bypass Damper on an increase of the 0-10 VDC output signal. Thisis necessary because the signal is Direct Acting and is not configurableas a Reverse Acting Signal on the VCM controller.

R1 - Supply Fan (Enable)This is a non-configurable output.

R2 Thru 5 - User Configurable RelaysThese relays are configurable by the user. For all the available configu-ration options see the OE357 4 Relay Output Expansion Board sec-tion of this manual.

OE354 (4) Analog Input(1) Analog Output Expansion BoardAIN1 - Outdoor Air Humidity Sensor InputThis input is used to connect an Outdoor Air Humidity Sensor that,combined with the Outdoor Air Temperature Sensor reading, is used tocalculate a Dewpoint and/or Wetbulb Temperature. Outdoor AirDewpoint Temperature is used to activate the Dehumidification Modeon MUA and CAV configured units which utilize the Dual DamperMode (Hood On/Off) control feature. The Wetbulb Temperature is usedfor Economizer enthalpy control.

AIN2 – Indoor Air Humidity Sensor InputThe Indoor Air Humidity Sensor is used to activate DehumidificationMode on a VAV or CAV unit. The Sensor can be either a Wall MountedSpace Humidity Sensor or a Return Air Duct Mounted Humidity Sen-sor.

AIN3 - CO2 Sensor InputThis Sensor is required if you need to monitor Indoor Air Quality andmodify the Economizer operation based on levels of CO

2 in the space

or building you are monitoring. The CO2 Sensor can be either a Wall

Mounted CO2 Sensor or and Return Air Mounted CO

2 Sensor as re-

quired by your specific application.

AIN4 - Building Pressure Sensor InputThis Sensor is only required if you wish to configure the VCM Control-ler for Building Pressure Control. Building Pressure Control can beaccomplished by using one of two main control methods. One controlmethod uses the 0-10 VDC signal to control an Exhaust Fan VFD or anExhaust Damper Actuator for Direct Acting Pressure Control applica-tions. In addition, for Reverse Acting Pressure Control applications itcan control an Outdoor Air Damper Actuator. The other available con-trol method is to configure one of the Output Relays as an Exhaust Fanoutput which will activate the Exhaust Fan anytime the Building Pres-sure is above the Building Pressure Setpoint.

AOUT1 - Building Pressure Control SignalThis voltage signal (0-10 VDC) is used to provide an output signal to aBuilding Pressure Control device. The output signal can be connectedto either an Exhaust Fan VFD or an Exhaust Damper Actuator whenDirect Acting Building Pressure Control is required. When ReverseActing Building Pressure Control is required, the output signal wouldbe connected to an Outdoor Air Damper Actuator. When used in thisapplication the output signal must be configured for Reverse ActingOperation.

OE355 (4) Analog OutputExpansion BoardAOUT1 – Modulating Heating SignalThis output signal can be configured for either 0–10 VDC or a 2-10VDC output signal. This signal can be configured for either Direct Act-ing or Reverse Acting operation. This output signal is used to operate aModulating Heating Device to maintain the Heating Supply Air Tem-perature Setpoint.

AOUT2 – Modulating Cooling SignalThis output signal can be configured for either 0–10 VDC, 2-10 VDCor 1.5-5.0 VDC output signals. This signal can be configured for eitherDirect Acting or Reverse Acting operation. This output signal is used tooperate a Modulating Cooling Device to maintain the Cooling SupplyAir Temperature Setpoint. If your unit uses a Digital Compressor thismust be configured for a 1.5-5.0 VDC output signal.

AOUT3 – Return Air Damper SignalThis output signal is a Direct Acting 0–10 VDC output signal that isused to modulate a Return Air Damper Actuator in concert with a Re-turn Air Bypass Damper Actuator for PAC or DPAC control schemes.

AOUT4 – Return Air Bypass Damper SignalThis output signal is a Direct Acting 0–10 VDC output signal that isused to modulate a Return Air Bypass Damper Actuator in concert witha Return Air Damper Actuator for PAC or DPAC control schemes.

OE357 (4) Relay Expansion BoardsR6 – R21 User Configurable Relay OutputsRelays can be configured in any order but we recommend that they beconfigured in the following order:

1. Cooling stages

2. Heating stages

3. Warm–up Mode Command (for VAV Boxes)

4. Reversing Valve (for Air to Air Heat Pumps)

5. Reheat

6. Exhaust Fan

7. Pre-Heater (for Low Ambient Protection)

8. Alarm

9. Override

10. Occupied

11. Economizer

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VCM Controller36

By using all (4) of the available 4 Relay Expansion Boards and the 4relay outputs available on the VCM controller, you have the ability toconfigure up to a combined total of 20, Heating Stages, Cooling Stages,and options 3 through 11 listed above.

OE356 Binary Expansion Board #1

Note: The Binary Inputs require wet contacts (24 VAConly) to recognize an active input. If you provide drycontacts, the contact closure will not be recognized

BIN1 – Exhaust Hood On InputWhen this wet contact input closes the VCM controller switches fromIndoor Air Control to Outdoor Air Control. This is typically used onCAV applications requiring Dual Damper (Hood On/Off) Modes.

BIN2 - Dirty Filter Contact Closure InputThis wet contact input is required for Filter Status Indication and re-quires a Differential Pressure Switch to initiate “Dirty Filter” indica-tion.

BIN3 – Proof of Flow InputA Proof of Flow Switch that provides a wet contact closure wheneverthe HVAC unit Supply Fan is operating can be connected to this input.If the Proof of Flow Switch contact opens while the Supply Fan is op-erating, all Heating and Cooling is suspended or disabled. The Proof OfFlow Switch is an optional input. This means the VCM controller mustbe configured by the user to recognize this input signal.

BIN4 – Remote Forced Occupied Mode InputWhen this wet contact input closes, it will force the VCM controllerinto the Occupied Mode. When the Remote Forced Occupied Signal isremoved, the controller will revert to the Unoccupied Mode of opera-tion if no internal or external schedule has been configured or is ineffect when this occurs.

OE356 Binary Expansion Board #2BIN1 – Remote Forced Heating Mode InputThis wet contact input is used to provide a means for another BAS orcontrol device (by others) to force the unit into Heating Mode when itcloses. See the Note regarding Remote Force Mode Setting that fol-lows at the end of this section.

BIN2 - Remote Forced Cooling Mode InputThis wet contact input is used to provide a means for another BAS orcontrol device (by others) to force the unit into Cooling Mode when itcloses. See the Note regarding Remote Force Mode Setting that fol-lows at the end of this section.

Note: Remote Forced Heating or Cooling Modes require thatthe user enter zero values for both the Heating andCooling Setpoints for the HVAC Mode Enable. TheVCM Controller will then look for wet contactclosures on the Remote Forced Cooling Mode andRemote Forced Heating Mode inputs to enable theHVAC Modes. If both the Remote Forced Heating andRemote Forced Cooling Modes are active, the unit willoperate in Vent Mode. The unit may also be operatedin Vent Mode by providing a wet contact closuresignal to the Remote Occupied Input.

BIN3 – Smoke Detector InputThis wet contact input is used to initiate shutdown of the HVAC unitwhen a Smoke Detector (by others) contact closure occurs. The con-troller remains active and can initiate alarm relays.

BIN4 – Remote Forced DehumidificationThis wet contact input is used to provide a means for another BAS orcontrol device (by others) to force the VCM controller into Dehumidi-fication Mode.

Note: When using the Remote Forced Dehumidificationfunction the user must set the Dehumidification SptIndoor RH to 100% for the Remote ForcedDehumidification feature to function.

Inputs & Outputs

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Sequence Of OperationsOccupied/UnoccupiedMode of OperationThe VCM controller can utilize several methods for determining theOccupied Mode of Operation. These are:

Forced ScheduleRemote Forced Occupied SignalInternal SchedulePush Button Override Signal

Forced ScheduleThe VCM controller can be forced into the Occupied Mode by input-ting a Forced Schedule from any operator interface.

Remote Forced Occupied SignalWhen this wet contact input closes, it will force the VCM controllerinto the Occupied Mode. When the Remote Forced Occupied Signal isremoved, the controller will revert to the Unoccupied Mode of opera-tion if no Internal or External Schedule has been configured or is ineffect when this occurs.

Note: If the Remote Forced Occupied Mode is to be used, itis necessary to set all the Internal Week Schedules to‘0’ so that the Internal Schedule always commands theUnoccupied Mode.

Internal Week ScheduleAn Internal Week Schedule, which supports up to two start/stop eventsper day, is available for determining Occupied and Unoccupied Sched-ules. If you are using the Internal Schedule, an Optimal Start calcula-tion is also available. See the Scheduling Section of this manual formore information on the Optimal Start Feature.

Push Button Override SignalDuring Unoccupied hours, the user can force the VCM controller backto Occupied operation by pressing the Override Button on the SpaceTemperature Sensors for a period of less than 3 seconds. This initiatesthe Override or resets the Override Timer back to zero during Unoccu-pied hours of operation.

During Override operations, the user can cancel the Override by press-ing the Override Button for a period of time between 3 seconds and 10seconds. This restores the VCM controller to Normal Unoccupied Op-eration.

If the Override Button is held for more than 10 seconds, it causes aSpace Sensor Failure Alarm. This is due to the fact that the OverrideButton actually shorts the Space Temperature Sensor input to ground. Ifthis input is shorted to ground or left floating with no Space Tempera-ture Sensor detected for more than 10 seconds, it is considered a SpaceTemperature Sensor failure.

You can still use the Space Temperature Sensor input for an OverrideCommand even when a Space Temperature Sensor is not connected.Simply provide a Momentary Push-Button connected between AIN1and the Ground Terminal on the same terminal block. Follow the aboveprocedure for initiating Overrides, even on Supply Air Temperature Con-trolled Cooling only HVAC units.

HVAC Modes of OperationThere are 6 possible HVAC Modes of Operation. They are:

Vent ModeCooling ModeDehumidificationHeating ModeWarm-Up ModeOff Mode

Vent Mode OperationThis Mode only applies to the Occupied Mode of Operation. The VentMode is defined as the Supply Fan running with no Heating, Cooling orDehumidification demand.

Vent Mode can occur during the Occupied Mode if the Space, Return orOutdoor Air Temperature Sensors are selected as the HVAC Mode En-able Sensor. Vent Mode can also occur if the Supply Air TemperatureSensor is the HVAC Mode Enable Sensor and the VCM has been con-figured for Remote Forced Heating and Cooling. See the Remote Con-trol of HVAC Mode section in this manual for complete details.

Note: During Vent Mode, all Cooling and Heating Stages aredeactivated and the Economizer Damper is maintainedat a Minimum Position to provide fresh air into thebuilding. The Static Pressure is still maintained by theSupply Fan VFD or Zoning Bypass Damper Signalsince the Supply Fan is still operating in this Mode.

Cooling Mode OperationOccupied Cooling Mode occurs whenever the HVAC Mode Enable Tem-perature is above the HVAC Mode Enable Cooling Setpoint. Unoccu-pied Cooling Mode only occurs if a Space Temperature Sensor is con-nected to the VCM, or a broadcast of Space Temperature is being re-ceived from an Averaging Broadcast Controller and only then if theSpace Temperature is above the Cooling Setpoint.

The Mechanical Cooling will be disabled if the Outdoor Air Tempera-ture is below the Cooling Lockout Setpoint by 1°F. This gives a 2°Fhysteresis around the Cooling Lockout Setpoint to prevent unwantedcycling in and out of Mechanical Cooling Mode. If the Outdoor AirTemperature disables the Mechanical Cooling while it is currently op-erating, the Mechanical Cooling will stage off if all staging and runtimes are satisfied.

If the Economizer has been enabled for operation, it is used as the firststage of Cooling and the Mechanical Cooling will be activated if neces-sary. See the Economizer Operation section for a more detailed operat-ing sequence.

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VCM Controller38

No matter which Sensor is configured for the HVAC Mode Enable or ifthe Remote BAS sets the Mode through Remote Forced Cooling, theSupply Air Temperature is always controlled to the Active Supply AirTemperature Setpoint while in the Cooling Mode..

Stage Control WindowThe Cooling Stage Control Window Setpoint determines when the com-pressors start to stage up and stage down. In the Cooling Mode, as theSupply Air Temperature rises above the Active Supply Air TemperatureSetpoint, the Cooling Stages will begin to stage on based on the Cool-ing Stage Up Delay setting. The Cooling Stages will continue to rununtil the Supply Air Temperature drops below the Active Supply AirTemperature Setpoint minus the Cooling Stage Control Window. Forexample if the Supply Air Temperature Setpoint is 55° and the CoolingStage Control Window is 5°, as the Supply Air Temperature drops be-low 50°, the Cooling Stages will begin to stage off based on the Cool-ing Stage Down Delay setting.

Cooling Staging DelayMinimum Off TimeA Cooling Stage cannot be activated unless it has been off forthis amount of time.

Minimum Run TimeAfter a Cooling Stage has been activated, it must remain on forthis amount of time.

Staging Up DelayAfter the first Cooling Stage has been activated, this delayprevents additional stages from activating too quickly beforethey are needed to achieve the Active Supply Air TemperatureSetpoint.

Staging Down DelayAfter a Cooling Stage has met its Minimum Run Time and is notneeded, this delay prevents additional stages from deactivatingtoo quickly in case they are needed to maintain the ActiveSupply Air Temperature Setpoint Temperature.

Modulating CoolingThe Modulating Cooling Proportional Window is used to determinethe signal to the Modulating Cooling Source and is user adjustable.The Modulating Cooling signal is calculated based on the differentialbetween the Supply Air Temperature and the Active Supply Air Tem-perature Setpoint based on the Modulating Cooling Proportional Win-dow. The Maximum Signal Adjustment per Time Period is 10% and isnot user adjustable. The Minimum Signal Adjustment per Time Periodis based on the Modulating Cooling Proportional Window. The largerthe Modulating Cooling Proportional Window, the smaller the signaladjustment will be per Time Period. The Time Period is the delay be-tween another increase or decrease in the Modulating Cooling SourceSignal and is user adjustable. For example, if the Modulating CoolingProportional Window is 5°F, the signal would be adjusted 2% per °Feach Time Period above or below the Active Supply Air TemperatureSetpoint. When the Supply Air Temperature is above or below theActive Supply Air Temperature Setpoint by 5°F or more, the signalwould adjust 10% each Time Period.

The VCM can control one of two Modulating Cooling sources, such asa Chilled Water Valve or a Digital Compressor. Whichever source isused, the VCM will control the Modulating Cooling source to maintainthe Active Supply Air Temperature Setpoint.

A Digital Compressor is a Variable Capacity Compressor that has a 10to 1 turn down ratio. The VCM is capable of handling a single stageCooling unit with a Digital Compressor as its only stage. It is also ca-pable of handling multistage Cooling units with a Digital Compressor.The Digital Compressor is always the first stage of Cooling. On multi-stage Cooling units with a Digital Compressor, Fixed Capacity Com-pressors will stage up while the Digital Compressor modulates to achievethe Active Supply Air Temperature Setpoint. A three compressor Cool-ing unit with a Digital Compressor is the only special staging arrange-ment.

On three compressor Cooling units with a Digital Compressor, the firststage of Cooling is the Digital Compressor. The second stage of Cool-ing is a Fixed Capacity Compressor, equal to the maximum capacity ofthe Digital Compressor. The third stage of Cooling is a Fixed CapacityCompressor with double the capacity of the second compressor. Whenthe third stage of Cooling activates, the second stage (compressor) ofCooling deactivates. The fourth stage of Cooling is when the secondstage (compressor) of Cooling is reactivated. In this way, a three com-pressor Cooling unit with a Digital Compressor becomes four stages ofCooling.

If the Supply Air Temperature rises above the Active Supply Air Tem-perature Setpoint, the Digital Compressor signal will modulate as neededup to 100%. When the Digital Compressor signal reaches 100% theCooling Stage Up Delay begins. If the Digital Compressor signal re-mains at 100% and the Cooling Stage Up Delay expires, an additionalFixed Capacity Compressor will activate if equipped.

If the Supply Air Temperature falls below the Active Supply Air Tem-perature Setpoint, the Digital Compressor signal will modulate as neededdown to 0%. When the Digital Compressor signal reaches 0% the Cool-ing Stage Down Delay begins. If the Digital Compressor signal remainsat 0% and the Cooling Stage Down Delay expires, the Digital Com-pressor, or a Fixed Capacity Compressor will be deactivated. The Digi-tal Compressor is always the last compressor to be deactivated.

Economizer OperationThis section assumes you have configured your HVAC unit to controlthe Outdoor Air Dampers in an Economizer Mode of operation.

The Economizer is used as the first stage of Cooling if the Outdoor Airor Wetbulb Temperature is below the Economizer Enable Setpoint. ForWetbulb control of the Economizer, an Outdoor Air Humidity Sensormust be installed. If the unit is equipped with a Return Air TemperatureSensor, the Outdoor Air or Wetbulb temperature must be at least 5°Fcolder than the Return Air Temperature to allow the Economizer to modu-late. The same is true if the unit is only equipped with a Space Tempera-ture Sensor. By using the Return Air and/or Space Temperature refer-ence, it allows the VCM to calculate whether the Outdoor Air Tempera-ture will assist in Free Cooling.

The VCM Controller can monitor an Outdoor Air Humidity Sensor andcombine that reading with the Outdoor Air Temperature reading to cal-culate a Wetbulb Temperature. If this Wetbulb Temperature is not avail-able, just the Outdoor Air Temperature will be used. Whichever tem-perature is available, it must be below the Economizer Enable Setpointby 1°F to enable the Economizer during the Cooling Mode of opera-tion. When the temperature rises 1°F above the Economizer EnableSetpoint, the Economizer will be disabled and return to Minimum Posi-tion.

Sequence Of Operations

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As soon as the Cooling Mode is started, the Economizer will calculatea starting damper position based on the Outdoor Air Temperature andthe differential between the Supply Air Temperature and the ActiveSupply Air Temperature Setpoint. After it moves to this initial Setpoint,further adjustments will be made in small increments to fine tune thedamper position to maintain the Active Supply Air Temperature Setpoint.If the Economizer reaches 100% open and the Supply Air Temperatureis still too warm, the Mechanical Cooling will be enabled to operate toprovide additional stages of Cooling. Once a Mechanical Cooling Stagehas been activated, the Economizer will remain full open until the Me-chanical Cooling Stages are off or the Outdoor Air Temperature orWetbulb Temperature causes the Economizer to be disabled.

If the Economizer is not enabled to provide Cooling during the Occu-pied Mode, it will still maintain the Minimum Position programmed bythe user to provide minimum fresh air into the building. During theUnoccupied Mode, the Economizer will be closed. If during the Unoc-cupied Mode there is a call for Cooling and the Economizer is enabledby Outdoor Air Drybulb or Wetbulb temperature, it will modulate be-tween full closed and full open to provide Free Cooling.

The Supply Air Temperature must be above the Supply Air Tempera-ture Setpoint before the Mechanical Cooling can be activated.

Dehumidification ModeDuring the Dehumidification Mode the VCM activates Cooling to ex-tract moisture from the Supply Air and utilizes either Modulating HotGas Reheat, On/Off Hot Gas Reheat or Heating to warm the Supply Airbefore entering the building. Hot Gas Reheat is the standard form ofReheat. The HVAC unit’s Heat Source or a Heat Source located in theSupply Air Duct can be used for Reheat if the unit is not equipped withHot Gas Reheat. Please see the warning note that follows regardingapplications operating Heating and Cooling simultaneously

Warning: Simultaneous Heating and Cooling cannot beapproved unless the HVAC unit has beenspecifically designed for this purpose. A SpecialPrice Authorization (SPA) must be obtained fromthe AAON® factory for these applications to avoidwarranty and/or rating problems. WattMasterControls Inc. assumes no liability for anySimultaneous Heating and Cooling application if aSPA is not obtained from the AAON® Factory at thetime the HVAC unit is ordered.

When Heating is used for Reheat instead of Hot Gas Reheat, the VCMcan activate the Heat Source(s) discussed in the Heating Mode section.Heating can also be used in conjunction with Hot Gas Reheat to addadditional Reheat for applications that require a higher Supply AirDrybulb Temperature than what Hot Gas Reheat can provide. WhenHeating is used in conjunction with Reheat, the VCM restricts the Heat-ing to one form of Modulating Heat, or one stage of Gas or ElectricHeat.

Note: MODGAS II cannot be used in conjunction with HotGas Reheat to add additional Reheat.

For DX Cooling Stages, the VCM activates the Cooling Stages basedon the actual Evaporator Coil Temperature compared to the EvaporatorCoil Temperature Setpoint. The Evaporator Coil Temperature is calcu-lated by using the Suction Pressure Sensor and converting the pressureto temperature. For Digital Compressor units, the VCM will modulatethe Digital Compressor to maintain the Evaporator Coil TemperatureSetpoint and activate Fixed Capacity Compressors as necessary.

For Chilled Water units the VCM opens the Chilled Water Valve to afixed 100% position to provide full moisture removal capabilities.

If you configured your VCM Controller for Dehumidification control,you need to install a Humidity Sensor on the optional Analog InputExpansion Board. If the VCM is configured as a MUA unit, use anOutdoor Air Humidity Sensor. If the VCM is configured as a VAV orCAV unit, use an Indoor Air Humidity Sensor such as a Wall Mountedor Duct Mounted Sensor. If the VCM is to be used for Dual DamperModes during Occupied hours, use both Indoor and Outdoor Air Hu-midity Sensors. As an example this could be used in a kitchen applica-tion when you have a CAV unit using both Outdoor Air and Return Air.This unit could be configured to operate using Return Air when theExhaust Hood is off or 100% Outdoor Air when the Exhaust Hood ison.

If the unit is equipped with a Modulating Hot Gas Reheat board(MHGRV II), it is automatically detected by the VCM controller. InDehumidification Mode, as the Cooling causes the Supply Air Tem-perature to drop, the MHGRV II will bypass Hot Gas to the Hot GasReheat Coil, raising the Supply Air Temperature back up to the ActiveSupply Air Temperature Setpoint.

If the unit is equipped with an On/Off Hot Gas Valve, then one of therelays will be configured for Reheat. The Reheat Relay will be acti-vated if the Supply Air Temperature is less than the HVAC Mode En-able Heating Setpoint. The Hot Gas Reheat Relay will remain on dur-ing the Dehumidification Mode regardless of the Supply Air Tempera-ture. This is to insure a steady Supply Air Temperature.

On 100% Outdoor Air applications the Outdoor Air Dewpoint initiatesthe Dehumidification Mode when the Outdoor Air Dewpoint rises abovethe Outdoor Air Dewpoint Setpoint during the occupied Mode of op-eration. The Outdoor Air Dewpoint is calculated by using an OutdoorAir Temperature Sensor and an Outdoor Air Humidity Sensor.

On VAV or CAV applications the Indoor Air Humidity initiates Dehu-midification when the Indoor Air Humidity rises above the Indoor AirHumidity Setpoint during the occupied Mode of operation.

The Dehumidification Mode can be configured to have Dehumidifica-tion Priority. If configured, the VCM will enter the DehumidificationMode when the Dewpoint or Humidity is above the Setpoint regardlessof the current Heating or Cooling demands. The Reheat is always con-trolled to the Active Supply Air Temperature Setpoint. The Active Sup-ply Air Temperature Setpoint will change during Heating, Cooling orVent Modes. During the Vent Mode, the Supply Air Temperature Setpointwill be a Calculated Setpoint that is halfway between the HVAC ModeSetpoints.

Technical Guide

VCM Controller40

If Dehumidification Priority has not been configured, the VCM willonly enter the Dehumidification Mode and use Reheat during the VentMode. The Reheat will be controlled to a Calculated Supply Air Tem-perature Setpoint that is halfway between the HVAC Mode Setpoints.

Night Dehumidification can also be configured and is used primarilyfor CAV units that require an Unoccupied Mode of Dehumidification.Night Dehumidification is only activated when the Indoor Air Humid-ity is above the Indoor Air Humidity Setpoint during the UnoccupiedMode.

Remote Forced DehumidificationDehumidifcation Mode is normally controlled by using a Humidity Sen-sor connected to the (4) Analog Input (1) Analog Output ExpansionBoard input AIN1 or AIN2. If desired Dehumidification Mode can alsobe determined by using a remote BAS or other user supplied remotedevice. The VCM controller will check Binary Input Expansion Board#2 for a 24 VAC signal on BIN4. If the signal is present it will force theVCM controller into Dehumidifcation Mode regardless of the mode itis currently operating in if Dehumidification Priority Mode has beenconfigured. If Dehumidification Priority Mode has not been config-ured, the unit will only be forced into Dehumidification Mode if it isoperating in the Vent Mode during the time the remote signal is beingsupplied to input BIN4.

Note: When using the Remote Forced Dehumidificationfunction the user must set the Dehumidification SptIndoor RH to 100% for the Remote ForcedDehumidification feature to function.

Return Air Bypass Damper ControlThe return air bypass (RAB) damper is only used on constant air vol-ume units with space temperature configured as the HVAC Mode En-able sensor. The RAB damper is only active during the dehumidifica-tion mode and is used as the first form of reheat. If the HVAC unit isequipped with modulating hot gas reheat, the RAB damper needs to beat 100% before the modulating hot gas reheat can be used. The RABdamper modulates from 0-100% as the space temperature falls belowthe cooling setpoint. When the space temperature is equal to the cool-ing setpoint, the RAB damper will be at 0%. When the space tempera-ture falls to halfway between the cooling and heating setpoints, the RABdamper will be at 100%.

If the HVAC unit is equipped with separate actuators for the outdoor airand return air dampers, the return air damper will proportionally closemore as the RAB damper opens. The rate at which the return air dampercloses is user adjustable. The purpose of closing the return air dampermore as the RAB Damper opens, is to allow more air to bypass theevaporator coil through the RAB Damper. If you want more air to passthrough the RAB Bypass Damper, enter a larger number in the ReturnAir Damper Factor setpoint. If you want less air to pass through theRAB Damper, enter a smaller number in the Return Air Damper Factorsetpoint.

Heating Mode OperationOccupied Heating Mode occurs whenever the HVAC Mode EnableTemperature is below the HVAC Mode Enable Heating Setpoint. Un-occupied Heating Mode only occurs if a Space Temperature Sensor isconnected to the VCM or a broadcast of Space Temperature is beingreceived from an Averaging Broadcast Controller.

The Mechanical Heating will be disabled if the Outdoor Air Tempera-ture is above the Heating Lockout Setpoint by 1°F. This gives a 2°Fhysteresis around the Heating Lockout Setpoint to prevent unwantedcycling in and out of Mechanical Heating Mode. If the Outdoor AirTemperature disables the Mechanical Heating while it is currently op-erating, the Mechanical Heating will stage off if all staging and runtimes are satisfied.

No matter which Sensor is configured for the HVAC Mode Enable or ifthe Remote BAS sets the Mode through Remote Forced Heating, theSupply Air Temperature is always controlled to the Active Supply AirTemperature Setpoint while in Heating Mode.

Stage Control WindowThe Heating Stage Control Window Setpoint determines when theHeating Stages begin to stage up and stage down. In the Heating Mode,as the Supply Air Temperature falls below the Active Supply Air Tem-perature Setpoint, the Heating Stages will begin to stage on based onthe Heating Stage Up Delay. The Heating Stages will continue to rununtil the Supply Air Temperature rises above the Active Supply AirTemperature Setpoint plus the Heating Stage Control Window. Forexample if the Supply Air Temperature Setpoint is 140°F and the Heat-ing Stage Control Window is 5°F, as the Supply Air Temperature risesabove 145°F, the Heating Stages will begin to stage off based on theHeating Stage Down Delay.

Heating Staging DelayMinimum Off TimeA Heating Stage cannot be activated unless it has been off forthis amount of time.

Minimum Run TimeAfter a Heating Stage has been activated, it must remain on forthis amount of time.

Staging Up DelayAfter the first Heating Stage has been activated, this delayprevents additional stages from activating too quickly beforethey are needed to achieve the Active Supply Air TemperatureSetpoint.

Staging Down DelayAfter a Heating Stage has met its Minimum Run Time and is notneeded, this delay prevents additional stages from deactivatingtoo quickly in case they are needed to maintain the ActiveSupply Air Temperature Setpoint.

Sequence Of Operations

VCM Controller

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MODGAS II ControllerThe MODGAS II Controller is treated as a single stage of gas Heatingwhen connected to the VCM’s expansion port. The Supply Air Tem-perature is broadcast from the MODGAS II Controller to the VCM.The Supply Air Temperature Setpoint is broadcast from the VCM to theMODGAS II Controller. When the VCM enters the Heating Mode, itbroadcasts a command to activate the MODGAS II Controller. TheMODGAS II Controller modulates the Natural Gas Valve to maintainthe Supply Air Temperature Setpoint. See the MODGAS II ControllerTechnical Guide for detailed operation information of the MODGAS IIController.

MODGAS II Controllerwith Additional Stages of HeatThe VCM can activate the MODGAS II Controller and additional stagesof heating if needed. If this configuration is needed, a heating relaymust be configured on the VCM for the MODGAS II Controller, but itwill not be connected to anything. The MODGAS II Controller willalways be the first stage of heating in this configuration. Additionalheating relays can be configured and connected to Staged Heatingsources, such as Natural Gas or Electric Heat. In order for the addi-tional stages to activate, the MODGAS II Controller must be at 100%and then the Stage Up Delay begins. Once the Stage Up Delay expiresand the Gas Valve is still at 100%, another Fixed Stage of Heating willactivate. This will be the VCM’s second stage of heat. The MODGASII Controller will modulate to achieve the Active Supply Air Tempera-ture Setpoint. If the MODGAS II Controller modulates to 0% and theSupply Air Temperature is above the Active Supply Air Setpoint plusthe Heating Stage Control Window, the Stage Down Delay begins. Oncethe Stage Down Delay expires and the Supply Air Temperature hasremained above the Active Supply Air Setpoint plus the Heating StageControl Window, the Fixed Stage of Heating will be deactivated. TheMODGAS II will remain active, even at the minimum valve positionunless the Supply Air Temperature remains above the Active SupplyAir Setpoint plus the Heating Stage Control Window. The MODGAS IIcontroller will be the last stage of heating to be deactivated.

Modulating HeatingThe VCM supports various forms of Modulating Heat such as SCRElectric Heat, Modulating Hot Water Heat and Modulating Steam Heat.Whichever form of Modulating Heating is used, the VCM will modu-late the Heat Source to achieve the Active Supply Air TemperatureSetpoint. Modulating Natural Gas is a form of Modulating Heat, but iscontrolled by the MODGAS II Controller. The VCM only activates theMODGAS II as a stage of heat, therefore, the Modulating Heating Pro-portional Window does not apply when the VCM is connected to theMODGAS II Controller and is the only form of Heating activated bythe VCM.

The Modulating Heating Proportional Window is used to determine thesignal to the Modulating Heating Source and is user adjustable. TheModulating Heating Signal is calculated by the differential between theSupply Air Temperature and the Active Supply Air Temperature Setpointbased on the Modulating Heating Proportional Window. The maximumsignal adjustment per Time Period is 10% and is not user adjustable.The minimum signal adjustment per Time Period is based on the Modu-

lating Heating Proportional Window. The larger the Modulating Heat-ing Proportional Window, the smaller the signal adjustment will be perTime Period. The Time Period is the delay between another increase ordecrease in the Modulating Heating source signal and is user adjust-able. For example, if the Modulating Heating Proportional Window is5°F, the signal would be adjusted 2% per °F each Time Period above orbelow the Active Supply Air Temperature Setpoint. When the SupplyAir Temperature is above or below the Active Supply Air TemperatureSetpoint by 5°F or more, the signal would adjust 10% each Time Pe-riod.

The VCM can activate two forms of Heating that are classified as Pri-mary and Secondary Heat Sources. The Primary Heat Source used canbe SCR Electric Heat, Modulating Hot Water Heat or Modulating SteamHeat. The Secondary Heat Source used can be Modulating Natural Gas(MODGAS II Controller), Staged Gas Heat or Staged Electric Heat.

Primary Modulating Heat andSecondary Heat with MODGAS II ControllerThe Modulating Heating Proportional Window is used to determine thesignal to the Primary Heat Source and is user adjustable. The HeatingStage Control Window is used to determine stage up and stage down ofthe Secondary Heat Source. In the Heating Mode, the Primary HeatSource will modulate to achieve the Active Supply Air TemperatureSetpoint. When the Primary Heat Source reaches 100%, the HeatingStage Up Delay begins. If the Primary Heat Source is still at 100% afterthe Heating Stage Up Delay expires, the Secondary Heat Source willactivate, which is controlled by the MODGAS II Controller. The Pri-mary Heat Source will then be forced to 0%, allowing the MODGAS IIController to modulate the gas valve to achieve the Active Supply AirTemperature Setpoint. When the Secondary Heat Source reaches 100%,the Heating Stage Up Delay begins. If the Secondary Heat Source isstill at 100% after the Heating Stage Up Delay expires, the PrimaryHeat Source will be forced to 100%. The Primary Heat Source willremain at 100% to allow the Secondary Heat Source to modulate toachieve the Active Supply Air Temperature Setpoint. If the Supply AirTemperature rises above the Active Supply Air Temperature Setpointplus the Heating Stage Control Window, the Heating Stage Down De-lay begins. If the Supply Air Temperature is still above the Active Sup-ply Air Temperature Setpoint plus the Heating Stage Control Windowand the Heating Stage Down Delay expires, the Primary Heat Sourcewill forced to 0%. If the Secondary Heat Source modulates to 0%, theHeating Stage Down Delay begins. If the Secondary Heat Source re-mains at 0% and the Heating Stage Down Delay expires, the SecondaryHeat Source will be deactivated, and the Primary Heat Source willmodulate to achieve the Active Supply Air Temperature Setpoint. If theSupply Air Temperature rises above the Active Supply Air TemperatureSetpoint plus the Heating Stage Control Window, the Primary HeatSource modulates as needed to allow the Supply Air Temperature tocool off.

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Sequence Of OperationsPrimary Modulating Heat and Secondary Heat withStaged Gas or Electric HeatThe Modulating Heating Proportional Window is used to determine thesignal to the Primary Heat Source and is user adjustable. The HeatingStage Control Window is used to determine stage up and stage down ofthe Secondary Heat Source. In the Heating Mode, the Primary HeatSource will modulate to achieve the Active Supply Air TemperatureSetpoint. When the Primary Heat Source reaches 100%, the HeatingStage Up Delay begins. If the Primary Heat Source is still at 100% afterthe Heating Stage Up Delay expires, the Secondary Heat Source willactivate. The Primary Heat Source will then modulate to achieve theActive Supply Air Temperature Setpoint. If the Secondary Heat Sourceis activated and the Primary Heat Source has modulated to 0%, theHeating Stage Down Delay will begin. If the Primary Heat Source isstill at 0% after the Heating Stage Down Delay expires, the SecondaryHeat Source will deactivate. If the Supply Air Temperature rises abovethe Active Supply Air Temperature Setpoint plus the Heating StageControl Window, the Primary Heat Source modulates to 0% to allowthe Supply Air Temperature to cool off.

Warm-up Mode OperationWhen the VCM Controller switches to the Occupied Mode of Opera-tion (Not Override Mode), the unit compares the Return Air Tempera-ture to a Morning Warm-up Target Temperature. If the Return Air Tem-perature is below this Setpoint, the Warm-up Mode is initiated. ThisMode remains in effect until the Return Air Temperature rises abovethe Target Temperature or a user adjustable Time Period expires. Warm-up Mode is not initiated by Push Button Overrides or Unoccupied Heat-ing demands.

Once the Warm-up Mode has been terminated, it cannot resume untilthe unit has been through a subsequent Unoccupied Mode. Only oneWarm-up Mode is allowed per Occupied cycle.

If you have stand alone VAV boxes that need to be forced wide openduring the Warm-up Mode, you can configure one of the relay outputsto be used during this Mode. If the Warm-up Mode is active, the relay isactivated. This relay then becomes the Force Open Command for allVAV boxes to which it is wired.

Off ModeIf the schedule has set the Unoccupied Mode and no Heating, Coolingor Dehumidification demands exist, the VCM Controller enters the OffMode. During the Off Mode the Supply Fan is off and the Outdoor AirDampers are closed.

Remote Control of HVAC Mode

Note: When using the Remote Control Of HVAC Mode bothof the Heating and Cooling HVAC Mode EnableSetpoints must be set to zero.

The Heating Mode, Cooling Mode and Vent Mode can be determinedby a remote Building Automation System (BAS). The VCM will checkthe Binary Input Expansion Board #2 for a 24 VAC input signal onBIN1 and BIN2. BIN1 is used for Remote Forced Heating Mode. BIN2is used for Remote Forced Cooling Mode. If a 24 VAC signal is present

on both BIN1 and BIN2, the VCM will be in Remote Forced VentingMode. Remote Forced Venting Mode is considered to be Occupied FanOnly operation. Once the Remote Forced Mode has been set, normalHeating, Cooling or Venting Modes of operations will occur. All otheruser adjustable setpoints, such as the Heating and Cooling Supply AirTemperature Setpoints are used in the actual control of the equipment.

During Dehumidification, if a Reset Source is not configured, the Sup-ply Air Temperature Setpoint will be 70°F.

The Remote Occupied Input on the Binary Input Expansion Board #1,BIN4 can also be used for Occupied Fan Only operation when the Re-mote Forced Heating or Cooling inputs are not activated.

Supply Air TemperatureSetpoint ResetThe VCM incorporates a new automatic Supply Air Temperature Resetcapability. During reset, the Supply Air Temperature Setpoints are al-ways being calculated based on the Heating and Cooling demands ofthe reset source. Since the Supply Air Temperature Setpoints are notfixed during reset, we refer to them as the “Active Supply Air Tempera-ture Setpoints”.

The Supply Air Temperature Setpoints can automatically be reset byconfiguring the Space Temperature or Return Air Temperature as theSAT/Reset Source. The Supply Air Temperature Setpoints can also bereset by configuring the Fan VFD Signal or Remote SAT Reset as theSAT Reset Source. The Fan VFD Signal and Remote SAT Reset op-tions are not fully automatic and require the user to enter a Low and aHigh Temperature Reset setpoint for both Heating and Cooling.

If Space Temperature or Return Air Temperature is configured as theSAT/Reset Source, the user will need to enter the desired Heating andCooling Setpoints for the SAT/Reset Source. The VCM uses the HVACMode Enable Setpoints to determine the mode of operation. Once theHVAC Mode has been determined, the VCM calculates the Active Sup-ply Air Temperature Setpoint based on the SAT/Reset Source Tempera-ture in relation to the SAT/Reset Source Heating and Cooling Setpoints.During the Dehumidification Priority Mode, the Active Supply Air Tem-perature Setpoint is calculated in the same way as the Heating or Cool-ing Modes. When the VCM is in the Venting Mode, the Supply AirTemperature Setpoint will be calculated to be halfway between theHVAC Mode Enable Setpoints. When the VCM is in DehumidificationPriority and the HVAC Mode is the Vent Mode, the Supply Air Tem-perature Setpoint reset range will be + or - 10° F, above and below thecalculated Vent Mode, Supply Air Temperature Setpoint.

If the Fan VFD Signal is configured as the SAT/Reset Source, the SAT/Reset Source Setpoints and Remote SAT Reset Setpoints create the rangeof Supply Air Temperature Reset from 0% to 100% Supply Fan VFDSignal. When the Supply Fan VFD signal is at 0%, the SAT/Reset Sourceheating setpoint will be the lowest Supply Air Temperature setpoint forheating. When the Fan VFD signal is at 100% , the Remote SAT Resetheating setpoint will be the highest Supply Air Temperature setpointfor heating. When the supply fan VFD signal is at 0%, the Remote SATReset cooling setpoint will be the highest Supply Air Temperature

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setpoint for cooling. When the supply fan VFD signal is at 100%, theSAT/Reset Source cooling setpoint will the lowest Supply Air Tem-perature setpoint for cooling. During the dehumidification priority mode,the Active Supply Air Setpoint is calculated in the same way as theHeating or Cooling Modes. When the VCM is in the Vent Mode, theSupply Air Temperature Setpoint will be calculated to be halfway be-tween the HVAC Mode Enable Setpoints.

If Remote SAT Reset is configured as the SAT/Reset Source, the SAT/Reset Source Setpoints will be the lowest Supply Air TemperatureSetpoints for both Heating and Cooling when the Remote SAT ResetInput is at 0 VDC. When the Remote SAT Reset Input is at 5 VDC, theRemote SAT Reset Setpoints will be the highest Supply Air Tempera-ture Setpoints for both Heating and Cooling. The supply air setpointwill proportional between the SAT/Reset Source Setpoints at 0 VDCand the Remote SAT Reset Setpoints at 5 VDC. During the Dehumidi-fication Priority Mode, the Supply Air Temperature Setpoints will bethe same as the Heating and Cooling Modes. When the VCM is in theVent Mode, the Supply Air Temperature Setpoint will be calculated tobe halfway between the HVAC Mode Enable Setpoints.

Supply Fan ControlAnytime the Supply Fan is requested to start, a timer is checked tomake sure the Supply Fan has been off for at least 1 minute. This 1minute delay is to protect against rapid cycling of the Supply Fan. Oncethe 1 minute delay has been satisfied, the Supply Fan relay is activatedand all other outputs are verified to be in the off condition for a periodof 1 to 2 minutes. This short period of Supply Fan only Operationserves to purge the stagnant air from the duct before any Heating orCooling occurs.

Normally the Supply Fan runs continuously during the Occupied Modeof operation. If the fan is only required to run in the Occupied Modeduring Heating, Cooling or Dehumidification Modes, the VCM can beconfigured for Fan Cycle Mode.

Duct Static Pressure ControlThe VCM Controller reads and controls Static Pressure in the duct sys-tem if the Supply Fan has been configured for Duct Static PressureControl. Anytime the Supply Fan is operating, the VCM Controller iscontrolling Duct Static Pressure. The Duct Static Pressure Setpoint andDeadband limits are user adjustable along with a Control Interval. ThisControl Interval is the amount of time that elapses between each adjust-ment to the Duct Static Pressure Control Output Signal. The defaultperiod is 10 seconds and should not be changed unless close observa-tion reveals that the Supply Fan is hunting and not maintaining a stablepressure reading. The Static Pressure Control Output Signal can be usedto control a Supply Fan VFD (Direct Acting Operation) or a ZoningBypass Damper Actuator (Reverse Acting Operation).

The Duct Static Pressure Control Output Signal is a non-configurableDirect Acting Signal (0-10 VDC). This Output Signal can be used todirectly connect to a Supply Fan VFD. The Output Signal increases(Increases VFD Speed) if the Duct Static Pressure is below the DuctStatic Pressure Setpoint by the Deadband amount and the Output Sig-nal decreases (Decreases VFD Speed) if the Static Pressure is above theSetpoint by the Deadband amount.

Since the Duct Static Pressure Control Output Signal is a non-configurable Direct Acting Signal (0-10 VDC), when you are using aZoning Bypass Damper Actuator to control the Duct Static Pressureyou must set up the Zoning Bypass Damper Actuator or the ZoningBypass Damper so that it is Reverse Acting in operation. The OutputSignal increases (closes Zoning Bypass Damper) if the Duct Static Pres-sure is below the Duct Static Pressure Setpoint by the Deadband amountand the Output Signal decreases (opens Zoning Bypass Damper) if theStatic Pressure is above the Setpoint by the Deadband amount.

If the Static Pressure ever rises 0.5” above the Duct Static PressureSetpoint, the Duct Static Pressure Control Output Signal will be cut inhalf every control period until the Static Pressure is brought under con-trol. This is to prevent damage to the ductwork if all the VAV boxes areclosed or some other blockage occurs in the ductwork.

Warning: The manufacturer does not assume responsibilityfor protecting the equipment from overpressurization! The user should always installmechanical high static protection cutoffs to protecttheir system!

When the Supply Fans starts, the Duct Static Pressure Control OutputSignal will go to the Minimum % for Heating. Anytime the Supply Fanis off the Duct Static Pressure Control Output Signal will remain at zerovolts.

If the Supply Fan control is not configured for Duct Static PressureControl, you can still monitor the Duct Static Pressure if the Duct StaticPressure Sensor is installed, however no control will occur.

Building Pressure ControlThe VCM can maintain Building Static Pressure anytime the SupplyFan is operating by activating a Constant Volume Exhaust Fan, a VFDExhaust Fan, Modulating Exhaust Damper or by modulating the Out-door Air Damper. A Building Pressure Transducer must be connected tothe VCM’s Analog Input Expansion Board. For Constant Volume Ex-haust Fan applications, only an Exhaust Fan Relay needs to be config-ured for on/off operation of the Exhaust Fan. VFD or Modulating Build-ing Pressure control must be configured in order to operate. An Ex-haust Fan Relay can also be configured along with Modulating Build-ing Pressure control for an Enable output. Building Pressure can bemaintained by either Direct or Reverse Acting control.

Direct ActingIf configured, a VFD Exhaust Fan or Modulating Exhaust Damper willbe controlled by varying a 0-10 or 2-10 VDC control signal on theanalog output of the optional Analog Input Expansion Board. If an en-able output is required, an Exhaust Fan Relay can also be configured.The Exhaust Fan Relay and the Modulating Signal will activate whenthe Building Static Pressure rises above the Building Static PressureSetpoint plus the Deadband. The Exhaust Fan Relay will remain activeuntil the Building Static Pressure falls below the Building Static Pres-sure Setpoint minus the Deadband and the Modulating Signal falls to0%.

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On/Off ControlIf you do not require a Modulating Control Signal, you can also config-ure one of the Relay Outputs as an Exhaust Fan Relay to activate when-ever the Building Static Pressure is above the Building Static PressureSetpoint plus the Deadband. The Exhaust Fan Relay will deactivatewhen the Building Static Pressure falls below the Building Static Pres-sure Setpoint minus the Deadband. Only one Relay Output should beconfigured for this operation. There is no staging of additional ExhaustFan Relays.

Reverse ActingIf configured, on a drop in building static pressure below the buildingpressure setpoint minus the deadband, the AOUT 1 terminal on theAnalog Input Expansion Board will modulate the 2-10 VDC signal toopen the outside air damper. When this option is selected, no econo-mizer free cooling or IAQ operation will be available.

IAQ (CO2) Operation

If you have configured the VCM Controller to monitor and control CO2

levels, the Economizer operation will be modified as follows:

1. The Maximum Reset Position the Economizer can open tois determined by a user adjustable setpoint called the CO

2

Protection Limit Max. Level.

2. The Minimum Position the Economizer can close down tois Reset higher as the level of CO

2 increases above the CO

2

Protection Limit Max Level programmed by the user. Asthe CO

2 level increases above the adjustable CO

2 Setpoint,

the Outdoor Air Damper will start opening beyond itsMinimum Position. At the CO

2 Protection Limit Reset

Range above Setpoint, the Economizer will be held to itsMaximum Reset Position and not allowed to open anyfurther.

Pre-heater OperationIn colder climates where freezing temperatures are sometimes experi-enced, it is desirable to preheat the Outdoor Air being drawn into theHVAC unit before it reaches the Water Coils to prevent freezing. ThePre-heater control option is available by setting a Low Ambient Protec-tion Setpoint and by configuring one of the relay outputs as a Pre-Heater.Only one relay can be configured for this option and therefore stagingof Pre-heater relays is not available.

The Pre-heater sequence operates so that anytime the Outdoor Air Tem-perature is below the Low Ambient Protection Setpoint and the SupplyFan is running, the Pre-heater Relay will activate. It will remain onuntil the Outdoor Air Temperature rises 1°F above the Setpoint or theSupply Fan shuts down. If the Proof Of Flow option is installed andconfigured, its signal must also be active for the Pre-Heater Relay toactivate. This output will operate during any HVAC Mode that exists.

Outdoor Air LockoutsThe Outdoor Air Cooling and Heating Lockouts Setpoints are designedto prevent unwanted Mechanical Heating or Cooling operation duringcertain Outdoor Ambient Temperature conditions.

When the Outdoor Air Temperature is below the Cooling LockoutSetpoint, no Mechanical Cooling can operate. However, if the unit isequipped with an Economizer and the VCM is configured to use theEconomizer, it can be used to provide free Cooling when the Mechani-cal Cooling is locked out. For Air to Air Heat Pumps the Cooling lock-out also applies to Compressor Heating, which means it usually will bea lower setting than on Cooling units that are not Air to Air Heat Pumps.

The Outdoor Air Heating Lockout operates so that when the OutdoorAir Temperature is above the Outdoor Air Heating Lockout Setpoints,no Mechanical Heating can operate. This applies to any type of Heatingexcept Compressor Heating as used on Air to Air Heat Pumps. Thelockout for Compressor Heating is explained in the previous paragraphregarding Cooling Lockout Setpoints.

Supply Air CutoffsThe Supply Air Temperature Cutoffs are designed to prevent extremelyHigh and Low temperature Supply Air from entering the building.

High Supply Air Temperature CutoffHigh Supply Air Temperature Cutoff is initiated when the Supply AirTemperature rises above the HI SAT Cutoff Setpoint. When this oc-curs, Heating stages will be deactivated until the Supply Air Tempera-ture falls 5 °F below the HI SAT Cutoff Setpoint.

Low Supply Air Temperature CutoffLow Supply Air Temperature Cutoff is initiated when the Supply AirTemperature falls below the LO SAT Cutoff Setpoint. If the VCM is inEconomizer Operation, Vent Mode or Heating Mode and the SupplyAir Temperature falls below the LO SAT Cutoff Setpoint for 10 min-utes, it is assumed a Mechanical Failure has occurred and all Heatingwill be deactivated, the Supply Air Fan will shut off and the OutdoorAir Dampers will close. If the VCM is in the Cooling or Dehumidifica-tion Mode and the Supply Air Temperature falls below the LO SATCutoff Setpoint, the Cooling Signal or Cooling Stages will immediatelybegin deactivating. To restore normal operation, one of the followingthree things must occur:

1. The Supply Air Temperature rises above the LO SATCutoff Setpoint by 5 °F

2. The VCM goes from Occupied to Unoccupied orUnoccupied to Occupied Mode.

3. The VCM’s power is cycled.

SchedulingThe VCM Controller has an internal power source for the Real TimeClock (RTC) that allows the controller to keep the time and accuratelycontrol scheduling. It can also broadcast the time to the VAV/Zone Con-trollers if that option is configured.

The VCM Controller has an Internal 7 day Schedule with 2 Start/StopEvents per day. You can also have 1 Holiday Schedule with 2 Start/StopEvents per day. This Holiday Schedule can be used for 14 differentHoliday periods.

Sequence Of Operations

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You can change the time on the VCM Controller through the ModularService Tool or the System Manager. You can also broadcast the timeand date to all VCM controllers by using a Personal Computer and thePRISM II Computer Front End Software.

The Internal Scheduling in the VCM Controller also includes a SelfTeaching Optimal Start Routine that can be activated by entering a valueof 1.0 or greater for the Soak Multiplier Setpoint. The Optimal Startfunction can only be used if your VCM Controller has a Space Tem-perature Sensor installed and it is being used as the Controlling Sensor,or you are using WattMaster VAV/Zone controllers with the VCM con-troller. No adjustments other than the Soak Multiplier are required fromthe user because the VCM Controller monitors how long it takes toreach the Target Temperature each day and adjusts the Starting Timeaccordingly. That means the first day you operate your HVAC unit itwill not be able to Optimally Start because it does not have a history ofprevious Starts and their results. After the first day, the VCM Controllerwill begin adjusting the Start Time, and after six Normally ScheduledStarts have occurred, the Optimal Start Routine will have gatheredenough data to provide an accurate Pre-start based on the learned con-ditions. This is an ongoing learning process of the six previous starts,so the unit automatically adjusts for the changing seasons. If you don’tneed this feature but you are using the Space Temperature Sensor as theControlling Sensor, you can set the Soak Multiplier to zero to eliminatethe Optimal Start Routines.

Internal Trend LoggingThe VCM Controller continuously maintains an Internal Trend Log,which records a fixed set of values at an interval programmed by theuser. These values can be retrieved only with the PRISM II ComputerFront End Software. If you do not have a computer with PRISM IISoftware installed and connected to the system communications loop,you do not have access to these logs.

There are 120 log positions available. Once the last (120th) positionhas been recorded, the log jumps back to the first position and beginsoverwriting the old data. This means the user is required to retrieve thelogs at an interval that is shorter than the duration of the last 120 logs.

Shown below are some log intervals and the duration of 120 logs.

1 Minute Interval = 2 Hours

12 Minute Interval = 24 Hours

15 Minute Interval = 30 Hours

30 Minute Interval = 60 Hours

60 Minute Interval = 120 Hours

The fixed items in the log are listed below:

Date

Time

Space Temperature

Return Air Temperature

Outdoor Air Temperature

Active Cooling Setpoint

Active Heating Setpoint

Supply Air Temperature

Active Supply Air Temperature Setpoint

Outdoor Air Humidity

Indoor Air Humidity

Duct Static Pressure

Building Static Pressure

Economizer Signal Percentage

Supply Fan VFD/Zoning Bypass Damper Signal Percentage

Exhaust Fan VFD/Exhaust Damper Signal Percentage

Modulating Heat Signal Percentage

Modulating Cool Signal Percentage

On Board Relay Status (BIT Pattern )

Expansion Board Relay Status (BIT Pattern )

These items and values are explained in greater detail in the PRISM IIComputer Front End Software manual.

Force Modes or OverridesThe VCM Controller relay and analog outputs can be user overridden ifthe Modular Service Tool or the PRISM II Computer Front-end Pro-gram is used. The System Manager cannot be used for these ForceModes. The Modes of operation for the relays are:

0 = Normal Operation

1 = Forced ON

2 = Forced OFF

The Analog Outputs are Forced if the user specifies a value between 0.0and 10.0 VDC. To cancel the Force Mode, you must enter a value lessthan 0 such as -1.0 VDC.

When the Analog Outputs are Forced, the display on the Modular Ser-vice Tool or Prism II program can be interpreted as the actual voltage.During normal operation, the display indicates the percentage signalapplied based on the user defined voltage limits. For example, if theuser defines a 2.0 VDC to 10.0 VDC range, then 50% would be 6.0VDC instead of the 5.0 VDC applied when the range is 0.0 VDC to10.0 VDC.

As previously mentioned, Force Modes can only be activated whenusing either the Modular Service Tool or the PRISM II Computer FrontEnd Software. Furthermore, the Override condition can only remain ineffect as long as one of these Operator Interface devices is connectedand communicating with the VCM. That means that you cannot Forcean Override condition and then walk away from the equipment with theOverride still active. The loss of communications, removal or shutdownof the Operator Interface will automatically terminate the Override within10 minutes. This is to protect the equipment and to prevent an Overridecondition from remaining active indefinitely resulting in inefficient ordangerous operation of the equipment.

Warning: No equipment protection is available during theForce Mode of operation. That means youcould start a compressor without running theSupply Fan or create other conditions thatWILL damage the equipment. WattMasterControls, Inc. assumes no responsibility orliability for the misuse of these user Overridesthat cause damage to the equipment!

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VCM Controller46

Sequence Of OperationsVAV/Zone Box CompatibilityThe VCM Controller is designed to communicate with Orion VAV/ZoneControllers. The VCM can be configured to broadcast its Internal Sched-ule, Time and Date, Fan and Heat Status and Supply Air Temperature.The VCM can also broadcast Force to Max or Force to Fixed Positionduring Morning Warm-up. The Orion VAV/Zone Controllers broadcastPush-Button Overrides from Unoccupied to Occupied. They can alsogenerate Unoccupied Heating and Cooling calls to the VCM controllerbased on Setbacks.

If you are using another manufacturers VAV Box Controllers, the VCMController can activate a relay to inform the VAV/Zone Controllers thatthe VCM controller is operating in Warm-up Mode. No other informa-tion can be passed between the VCM Controller and the other manufac-turers VAV Box Controllers. This means that Overrides or UnoccupiedHeating and Cooling calls cannot activate the VCM Controller. If youneed any of these capabilities you must use only Orion VAV/Zone con-trollers for controlling all your VAV Boxes.

VAV/Zone SystemWhen the VCM goes into the Occupied Mode it initiates Morning Warm-up if the Return Air Temperature is below the Morning Warm-up TargetTemperature Setpoint. During Morning Warm-up the VAV/Zone Con-trollers will modulate open if the Space Temperatures are too cold. Theycan also move to their Maximum Airflow or Fixed Airflow PositionSetpoint if they receive this broadcast from the VCM Controller. OnceMorning Warm-up has been satisfied, the VCM enters the Cooling Modeand the VAV/Zone Controllers will modulate to satisfy their Space Tem-perature Setpoints. If the Space Temperature falls below the HeatingSetpoint, staged or modulating Reheat can be activated to warm thespace.

Communications between the VCM and the VAV/Zone Controllers arehandled by the MiniLink Polling Device. Alarm Polling and TenantOverrides are also monitored by the MiniLink Polling Device. TenantOverrides are overrides generated by the Space Temperature Sensor’spush button. The MiniLink Polling Device records the start and stoptimes and total run times of the overrides on a daily and monthly basis.A computer running Prism II Computer Front End Software is requiredto retrieve all data acquired by the MiniLink Polling Device.

Zoning SystemThe VCM Controller automatically configures itself for Voting Controlwhen the MiniLink Polling Device is installed and is configured as aVoting System. The VCM controller sets the HVAC Mode Enable tothe Return Air Temperature Sensor as soon as communication is ac-quired with the MiniLink Polling Device. If the VAV/Zone controllersare configured for Voting, the MiniLink Polling Device totals the Heat-ing and Cooling demands and determines which HVAC Mode the VCMshould be in. The MiniLink Polling Device broadcasts a forced Heat-ing, Cooling or Vent Mode of operation to the VCM. Once the VCMreceives the broadcast to set the HVAC Mode, it operates as previouslydescribed in the VCM Sequence of Operations. If communications arelost, the VCM returns to its own control and will maintain the HVACMode Enable Setpoints by using the Return Air Temperature Sensor asthe Controlling Sensor.

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Using LEDs To Verify OperationThe VCM controller is equipped with 4 LEDs that can be used as verypowerful troubleshooting tools. See Figure 29 for the LED locations.The LEDs and their uses are as follows:

“COMM”This LED will light up to indicate system communications.

“PWR”This LED will light up to indicate that 24 VAC power has been appliedto the controller.

“LED1”This is the diagnostic blink code LED. It will light up and blink outdiagnostic codes. LED1 also represents the tens column in the addressblink code.

“LED2”This is the diagnostic blink code LED. It will light up and blink outdiagnostic codes. LED2 also represents the ones column in the addressblink code.

PWR LED OperationsWhen the VCM Controller is powered up the “PWR” LED should lightup and stay on continuously. If it does not light up, check to be sure thatyou have 24 VAC connected to the board, that the wiring connectionsare tight and that they are wired for the correct polarity. The 24 VACpower must be connected so that all ground wires remain common. Ifafter making all these checks the PWR LED does not light up, pleasecontact WattMaster technical support for assistance.

COMM LED OperationsWhen power is applied to the controller, the “COMM” LED will alsolight up. If this is a Stand Alone System (one controller only on theloop) or an Interconnected System (several VCM controllers tied to-gether without a CommLink) the COMM LED will glow continuously.The COMM LED will flicker when you are connected to the VCMcontroller and you are entering setpoints with the Modular Service Toolor the System Manager. It will also flicker if this is a Networked Sys-tem. If this is a Networked System (the system has a CommLink in-stalled) the COMM LED should flicker rapidly indicating that the sys-tem is communicating. A “flicker” is defined as a brief moment whenthe LED turns off then back on. It may be easier to see this “flicker” ifyou cup your hand around the LED.

If the COMM LED does not operate as indicated above, first checkthe address switch setting. Verify the address switch as outlined in theDiagnostic LEDs Operations section. See Figure: 29 for completeaddress switch setting instructions.

Note: LED1 represents the tens column and LED2 representsthe ones column of the board address. If the address ofthe board is set to 59 with the address switch, thenLED1 will blink 5 times and then LED2 will blink 9times.

If the address switch setting is correct and the COMM LED still doesnot behave as indicated above, check to be sure the operators interfaceis connected correctly. If you are using the System Manager Opera-tors Interface it must be connected to VCM controller as shown inFigure 31, or anywhere on the local communications loop. If you areusing the Modular Service Tool, verify that it is plugged in securely tothe DIN connection on the VCM controller. See Figure 31 for DINconnector location.

If the COMM LED still does not behave correctly, check the voltages atthe communications terminal block. Be sure the board is powered upfor this test. Unplug the communications terminal block from the boardand check the DC voltage between T and SHLD and between R andSHLD. Check the voltage with a digital multimeter set to DC volts.The voltage should be between 2.4 to 2.5 VDC between SHLD andeither T or R. If your voltage is not in this range, you probably have adamaged driver chip that must be replaced.

For driver chip replacement instructions, please see the Orion ControlsSystem Installation & Troubleshooting Guide for more information orcontact the factory for further assistance.

COMM

PWR

LED1

LED2

R

SHLD

T

COMM

(COMM) Communications LED

OE331-21-VCMController Board

Communications TerminalsSystem Manager Can BeConnected Here With PigtailCable

(PWR) Power LED

(LED2) Diagnostic LED

(LED1) Diagnostic LED

DIN ConnectorFor ModularService Tool

Figure 31: LED Locations & Service Connections

Troubleshooting

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AppendixDiagnostic LEDs OperationWhen power is first applied, both LEDs will be off for (1) second. Atthis time both LEDs will blink to indicate the setting of the addressswitch and then extinguish for 5 seconds. Verify that the address switchsetting is correct by counting the number of blinks.

Blink Code Description LED #1Number

Of Blinks

LED #2Number

Of Blinks

Normal Operation 0 1

Supply Air Sensor Failure 1 2

Outdoor Air Sensor Failure 2 2

Space Sensor Failure 3 2

Mechanical Cooling Failure 1 3

Mechanical Heating Failure 2 3

Fan Proving Failure 3 3

Dirty Filter Alarm 4 3

Smoke Alarm 5 3

Low Supply Temperature Alarm 1 4

High Supply Temperature Alarm 2 4

Control Temp. Cooling Failure 3 4

Control Temp. Heating Failure 4 4

Push Button Override 1 5

Zone Override 2 5

Force Outputs Override 0 6

Table 2: LED Blink Code Interpretation

Note: LED1 represents the tens column and LED2 representsthe ones column of the board address. If the address ofthe board is set to 59 with the address switch, thenLED1 will blink 5 times and then LED2 will blink 9times.

If the address switch is not correct, remove the communication loopterminal plug from the controller and then the power terminal plug. Setthe address dip switches correctly. See Figure 29 for correct addressswitch setting instructions. After you are sure the address switch settingis correct, reconnect the power connection and then the communicationloop connection to the board.

Note: Power to the Controller being addressed must alwaysbe cycled after changing address switch settings inorder for the changes to take effect.

Reapply power to the controller and observe the blink code to verify theaddress is set correctly. If the LEDs now blink the correct address yourboard is addressed correctly. If they don’t light up at all, the board is notoperating correctly and could be defective. Once the board is done blink-ing the address then LED2 will blink continuously for 30 seconds whilethe board calibrates. Once the board is done calibrating the DiagnosticLEDs will blink a code every 10 seconds to indicate board status. SeeTable 2 for a list of the various blink codes and their meaning.

If all of these tests are made and the controller still doesn’t operate,please contact WattMaster Controls Technical Support group. You canreach WattMaster Controls Technical Support at 866-918-1100.

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System Configuration OptionsThe VCM controller can be used as a Stand Alone System (One VCMController Only), connected together on a Interconnected System (Mul-tiple VCM controllers Only), or connected together on a Network Sys-tem (Multiple VCM Controllers, VAV/Zone Controllers, or Add -onControllers) to form a complete Orion Controls System that can be pro-grammed and monitored with one or more of the available Orion Op-erator Interfaces.

For detailed information about the various Orion Controls Systems thatare available and their related wiring requirements and options, pleasesee the Orion Systems Technical Guide.

Operator InterfacesThe Orion Operator Interfaces are designed to provide for program-ming and monitoring of VCM controller(s) and/or any VAV/Zone orAdd-on Controller(s) connected to your Orion System. The OperatorsInterfaces available for use with the Orion Systems are:

• Modular Service Tool

• Modular System Manager

• Tactio SI - Touch Screen Interface

• Personal Computer with Prism II Computer Front EndSoftware Installed

You can use any one of these interfaces or all of them on the same OrionSystem.

Stand Alone SystemThe Stand Alone system is used when you have a single VCM control-ler only. Programming and status monitoring are accomplished by se-lecting and installing one or more of the Operator Interfaces.

See Figure 32 for a Typical Stand Alone System Layout diagram.

Interconnected SystemThe Interconnected system is used when you have multiple VCM con-trollers on your job. With this system you simply connect the control-lers together using WattMaster communications wire or 18 gauge 2conductor twisted pair with shield wire (Belden #82760 or equiva-lent). This allows for all controllers that are connected on the commu-nications loop to be programmed and monitored from one or more ofthe available Operator Interfaces connected on the communicationsloop.

See Figure 33 for a Typical Interconnected System Layout diagram.

Networked SystemIf you have 1 to 59 VCM controllers that require information sharing ,simply connect the controllers together using WattMaster communica-tions wire or 18 gauge 2 conductor twisted pair with shield wire (Belden#82760 or equivalent). The Networked Single Loop system requiresthat either a MiniLink PD communication interface or a CommLinkcommunication interface or both are purchased and wired into the com-munications loop in a similar manner to the VCM controllers.

The Networked Multiple Loop system is used when you have morethan 59 VCM controllers and/or are using multiple VCM controllersthat are connected to VAV/Zone controllers. These groups of control-lers are broken up into multiple “Local Loops” which connect to eachother via the “Network Loop”. Each individual MiniLink PD handlesits specific local loop’s communications requirements. The CommLinkcommunications interface handles all the communications between theindividual MiniLink PDs to form the network loop. Up to 60 local loopscan connected together with this configuration. This provides the capa-bility for over 3500 controllers to be networked together.

See Figure 34 for a Typical Networked System Layout diagram.

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OperatorInterfaces

TactioSI

Figure 32: Typical Stand Alone System Layout

Appendix

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Op

era

tor

Inte

rfaces

Tactio

SI

Fig

ure

33:

Typ

ical

Inte

rco

nn

ecte

d S

yste

m L

ayo

ut

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Op

era

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Inte

rfa

ce

s

Op

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tor

Inte

rfa

ce

s

Tactio

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Fig

ure

34:

Typ

ical

Net

wo

rked

Sys

tem

Lay

ou

t

Appendix

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Thermistor Sensor Testing InstructionsUse the resistance column to check the thermistor sensor while discon-nected from the controllers (not powered).

Use the voltage column to check sensors while connected to poweredcontrollers. Read voltage with meter set on DC volts. Place the “-”(mi-

nus) lead on GND terminal and the “+”(plus) lead on the sensor inputterminal being investigated.

If the voltage is above 5.08 VDC, then the sensor or wiring is “open.”If the voltage is less than 0.05 VDC, the sensor or wiring is shorted.

10 kOhm Type III Temperature SensorTestingThe following sensor voltage and resistance tables are provided to aidin checking sensors that appear to be operating incorrectly. Many sys-tem operating problems can be traced to incorrect sensor wiring. Besure all sensors are wired per the wiring diagrams in this manual.

If the sensors still do not appear to be operating or reading correctly,check voltage and/or resistance to confirm that the sensor is operatingcorrectly per the tables. Please follow the notes and instructions beloweach chart when checking sensors.

Temperature – Resistance – Voltage For Type III 10 K Ohm Thermistor Sensors

Temp

(ºF)

Resistance

(Ohms)

Voltage @Input (VDC)

Temp

(ºF)

Resistance

(Ohms)

Voltage @Input (VDC)

Temp

(ºF)

Resistance

(Ohms)

Voltage @Input (VDC)

-10 93333 4.620 60 14681 3.042 86 8153 2.297-5 80531 4.550 62 14014 2.985 88 7805 2.2420 69822 4.474 64 13382 2.927 90 7472 2.1875 60552 4.390 66 12758 2.867 95 6716 2.055

10 52500 4.297 68 12191 2.810 100 6047 1.92715 45902 4.200 69 11906 2.780 105 5453 1.80520 40147 4.095 70 11652 2.752 110 4923 1.68725 35165 3.982 71 11379 2.722 115 4449 1.57530 30805 3.862 72 11136 2.695 120 4030 1.46935 27140 3.737 73 10878 2.665 125 3656 1.36940 23874 3.605 74 10625 2.635 130 3317 1.27445 21094 3.470 75 10398 2.607 135 3015 1.18550 18655 3.330 76 10158 2.577 140 2743 1.10152 17799 3.275 78 9711 2.520 145 2502 1.02454 16956 3.217 80 9302 2.465 150 2288 0.95256 16164 3.160 82 8893 2.40758 15385 3.100 84 8514 2.352

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VCM Controller54

Appendix

OE265-03 Relative Humidity SensorTesting Instructions:Use the voltage column to check the Humidity Sensor while connectedto a powered expansion board. Read voltage with meter set on DC volts.Place the “-”(minus) lead on terminal labeled GND and the “+” lead on

OE265 Relative Humidity Transmitters – Humidity vs. Voltage For 0-5 VDC Sensors

Humidity

Percentage(RH)

Voltage @

Input

(VDC)

Humidity

Percentage(RH)

Voltage @

Input

(VDC)

Humidity

Percentage(RH)

Voltage @

Input

(VDC)

Humidity

Percentage(RH)

Voltage @

Input

(VDC)

0% 0.00 26% 1.30 52% 2.60 78% 3.90

2% 0.10 28% 1.40 54% 2.70 80% 4.00

4% 0.20 30% 1.50 56% 2.80 82% 4.10

6% 0.30 32% 1.60 58% 2.90 84% 4.20

8% 0.40 34% 1.70 60% 3.00 86% 4.30

10% 0.50 36% 1.80 62% 3.10 88% 4.40

12% 0.60 38% 1.90 64% 3.20 90% 4.50

14% 0.70 40% 2.00 66% 3.30 92% 4.60

16% 0.80 42% 2.10 68% 3.40 94% 4.70

18% 0.90 44% 2.20 70% 3.50 96% 4.80

20% 1.00 46% 2.30 72% 3.60 98% 4.90

22% 1.10 48% 2.40 74% 3.70 100% 5.00

24% 1.20 50% 2.50 76% 3.80

the AIN terminal that the Humidity sensor is connected to on the Ana-log Input/Output Expansion Board.

OE265 RH Sensor TestingThe chart below is used to troubleshoot the OE265 Relative HumiditySensors.

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OE271 Pressure Sensor Testing InstructionsUse the voltage column to check the Duct Static Pressure Sensor whileconnected to powered controllers. Read voltage with meter set on DCvolts. Place the “-”(minus) lead on GND terminal and the “+”(plus)lead on the 0-5 pin terminal on (JP1) with the jumper removed. Be sureto replace the jumper after checking.

OE258 Building Pressure Sensor Testing InstructionsUse the voltage column to check the Building Static Pressure Sensorwhile connected to a powered expansion board. Read voltage with meterset on DC volts. Place the “-”(minus) lead on terminal labeled GNDand the “+” lead on terminal AIN4 on the Analog Input/Output Expan-sion Board.

OE258 Building Pressure Sensor

Pressure@

Sensor(“ W.C.)

Voltage @

Input

(VDC)

Pressure@

Sensor(“ W.C.)

Voltage @

Input

(VDC)-0.25 0.00 0.01 2.60-0.24 0.10 0.02 2.70-0.23 0.20 0.03 2.80-0.22 0.30 0.04 2.90-0.21 0.40 0.05 3.00-0.20 0.50 0.06 3.10-0.19 0.60 0.07 3.20-0.18 0.70 0.08 3.30-0.17 0.80 0.09 3.40-0.16 0.90 0.10 3.50-0.15 1.00 0.11 3.60-0.14 1.10 0.12 3.70-0.13 1.20 0.13 3.80-0.12 1.30 0.14 3.90-0.11 1.40 0.15 4.00-0.10 1.50 0.16 4.10-0.09 1.60 0.17 4.20-0.08 1.70 0.18 4.30-0.07 1.80 0.19 4.40-0.06 1.90 0.20 4.50-0.05 2.00 0.21 4.60-0.04 2.10 0.22 4.70-0.03 2.20 0.23 4.80-0.02 2.30 0.24 4.90-0.01 2.40 0.25 5.000.00 2.50

OE271 Duct Static Pressure Sensor

Pressure@

Sensor(“ W.C.)

Voltage @

Input

(VDC)

Pressure@

Sensor(“ W.C.)

Voltage @

Input

(VDC)0.00 0.25 2.60 2.330.10 0.33 2.70 2.410.20 0.41 2.80 2.490.30 0.49 2.90 2.570.40 0.57 3.00 2.650.50 0.65 3.10 2.730.60 0.73 3.20 2.810.70 0.81 3.30 2.890.80 0.89 3.40 2.970.90 0.97 3.50 3.051.00 1.05 3.60 3.131.10 1.13 3.70 3.211.20 1.21 3.80 3.291.30 1.29 3.90 3.371.40 1.37 4.00 3.451.50 1.45 4.10 3.531.60 1.53 4.20 3.611.70 1.61 4.30 3.691.80 1.69 4.40 3.771.90 1.77 4.50 3.852.00 1.85 4.60 3.932.10 1.93 4.70 4.012.20 2.01 4.80 4.092.30 2.09 4.90 4.172.40 2.17 5.00 4.252.50 2.25

OE271 Pressure Sensor TestingThe table below is used to troubleshoot the OE271 Duct Static Pres-sure Sensors.

OE258 Pressure Sensor TestingThe table below is used to troubleshoot the OE258 Building PressureSensors.

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Appendix

OE275 Suction Pressure TransducerCoil Pressure – Temperature – Voltage Chart

Tem

per

atu

re°F

Pre

ssu

reP

SI

Sig

nal

DC

Vo

lts

Tem

per

atu

re°F

Pre

ssu

reP

SI

Sig

nal

DC

Vo

lts

20 43.03 1.19 51 85.79 1.88

21 44.21 1.21 52 87.54 1.91

22 45.40 1.23 53 89.30 1.93

23 46.59 1.25 54 91.06 1.96

24 47.77 1.27 55 92.82 1.99

25 48.96 1.29 56 94.58 2.02

26 50.14 1.31 57 96.34 2.05

27 51.33 1.32 58 98.10 2.08

28 52.52 1.34 59 99.86 2.10

29 53.70 1.36 60 101.62 2.13

30 54.89 1.38 61 103.60 2.16

31 56.25 1.40 62 105.58 2.20

32 57.61 1.43 63 107.56 2.23

33 58.98 1.45 64 109.54 2.26

34 60.34 1.47 65 111.52 2.29

35 61.70 1.49 66 113.50 2.32

36 63.06 1.51 67 115.48 2.35

37 64.42 1.53 68 117.46 2.39

38 65.78 1.56 69 119.44 2.42

39 67.14 1.58 70 121.43 2.45

40 68.51 1.60 71 123.65 2.49

41 70.06 1.63 72 125.87 2.52

42 71.61 1.65 73 128.09 2.56

43 73.16 1.68 74 130.31 2.59

44 74.71 1.70 75 132.53 2.63

45 76.26 1.73 76 134.75 2.66

46 77.82 1.75 77 136.97 2.70

47 79.37 1.77 78 139.19 2.74

48 80.92 1.80 79 141.41 2.77

49 82.47 1.82 80 143.63 2.81

50 84.02 1.85

OE275 Suction Pressure Transducer TestingUse the voltage column to check the Suction Pressure Transducer whileconnected to the VCM Controller. The VCM Controller must be pow-ered for this test. Read voltage with a meter set on DC volts. Place thenegative lead from the meter on a ground (GND) terminal located onthe VCM’s 12-pin terminal block. Place the positive lead from the meteron the AIN5 terminal located on the VCM’s 12-pin terminal block.

OE275 Suction Pressure TransducerTestingThe Evaporator Coil Temperature is calculated by converting the Suc-tion Pressure to Temperature. The Suction Pressure is obtained by us-ing the OE275 Suction Pressure Transducer which is connected into theSuction Line of the Compressor. See the OE275 Suction Pressure Trans-ducer, Pressure, Temperature and Voltage Chart. The chart shows a tem-

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Notes:

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Notes:

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Notes:

Form: OR-VCM-TGD-01A Printed in the USA November 2005All rights reserved Copyright 2005

WattMaster Controls Inc.• 8500 NW River Park Drive • Parkville, Mo. • 64152Phone: 866-918-1100 www.orioncontrols.com Fax (816) 505-1101